Vaporization device systems and methods

ABSTRACT

Vaporization devices and methods of operating them. In particular, described herein are vaporizer cartridges for controlling the power applied to a resistive heater.

CROSS REFERENCE TO RELATED APPLICATIONS

This patent application claims priority as a continuation-in-part ofU.S. patent application Ser. No. 15/053,927, titled “VAPORIZATION DEVICESYSTEMS AND METHODS,” filed on Feb. 25, 2016, which is acontinuation-in-part of U.S. patent application Ser. No. 14/581,666,filed on Dec. 23, 2014 and titled “VAPORIZATION DEVICE SYSTEMS ANDMETHODS”, Publication No. US-2015-0208729-A1, which claims priority toU.S. Provisional Patent Application No. 61/920,225, filed on Dec. 23,2013, U.S. Provisional Patent Application No. 61/936,593, filed on Feb.6, 2014, and U.S. Provisional Patent Application No. 61/937,755, filedon Feb. 10, 2014. This patent application also claims priority to U.S.Provisional patent application No. 62/294,281, titled “SECURELYATTACHING CARTRIDGES FOR VAPORIZER DEVICES,” filed on Feb. 11, 2016.Each of these applications are herein incorporated by reference in theirentirety.

INCORPORATION BY REFERENCE

All publications and patent applications mentioned in this specificationare herein incorporated by reference in their entirety to the sameextent as if each individual publication or patent application wasspecifically and individually indicated to be incorporated by reference.

BACKGROUND

Electronic inhalable aerosol devices (e.g., vaporization devices,electronic vaping devices, etc.) and particularly electronic aerosoldevices, typically utilize a vaporizable material that is vaporized tocreate an aerosol vapor capable of delivering an active ingredient to auser. Control of the temperature of the resistive heater must bemaintained (e.g., as part of a control loop), and this control may bebased on the resistance of the resistive heating element.

Many of the battery-powered vaporizers described to date include areusable batter-containing device portion that connects to one or morecartridges containing the consumable vaporizable material. As thecartridges are used up, they are removed and replaced with fresh ones.It may be particularly useful to have the cartridge be integrated with amouthpiece that the user can draw on to receive vapor. However, a numberof surprising disadvantages may result in this configuration, particularto non-cylindrical shapes. For example, the use of a cartridge at theproximal end of the device, which is also held by the user's mouth,particularly where the cartridge is held in the vaporizer device by afriction- or a snap-fit, may result in instability in the electricalcontacts, particularly with cartridges of greater than 1 cm length.

Described herein are apparatuses and methods that may address the issuesdiscussed above.

SUMMARY OF THE DISCLOSURE

The present invention relates generally to apparatuses, includingsystems and devices, for vaporizing material to form an inhalableaerosol. Specifically, these apparatuses may include vaporizers.

In particular, described herein are cartridges that are configured foruse with a vaporizer (e.g., vaporizer device) having a rechargeablepower supply that includes a proximal cartridge-receiving opening. Thesecartridges are specifically adapted to be releasably but securely heldwithin the cartridge-receiving opening of the vaporizer and resistdisruption of the electrical contact with the controller and powersupply in the vaporizer even when held by the user's mouth.

For example, described herein are cartridge devices holding avaporizable material for securely coupling with an electronic inhalableaerosol device. A device may include: a mouthpiece; a fluid storagecompartment holding a vaporizable material; a base configured to fitinto a rectangular opening that is between 13-14 mm deep, 4.5-5.5 mmwide, and 13-14 mm long, the base having a bottom surface comprising afirst electrical contact and a second electrical contact, a firstlocking gap on a first lateral surface of the base, and a second lockinggap on a second lateral surface of the base that is opposite firstlateral surface.

A cartridge device holding a vaporizable material for securely couplingwith an electronic inhalable aerosol device may include: a mouthpiece; afluid storage compartment holding a vaporizable material; a baseconfigured to fit into a rectangular opening that is between 13-14 mmdeep, 4.5-5.5 mm wide, and 13-14 mm long, the base having a length of atleast 10 mm, and a bottom surface comprising a first electrical contactand a second electrical contact, a first locking gap on a first lateralsurface of the base positioned between 3-4 mm above the bottom surface,and a second locking gap on a second lateral surface of the base that isopposite first lateral surface.

A cartridge device holding a vaporizable material for securely couplingwith an electronic inhalable aerosol device, the device comprising: amouthpiece; a fluid storage compartment holding a vaporizable material;a rectangular base having a pair of minor sides that are between greaterthan 10 mm deep and between 4.5-5.5 mm wide, and a pair of major sidesthat are greater than 10 mm deep and between 13-14 mm wide, a bottomsurface comprising a first electrical contact and a second electricalcontact, and a first locking gap on a first lateral surface of the basepositioned between 3-4 mm above the bottom surface, and a second lockinggap on a second lateral surface of the base that is opposite firstlateral surface. Any of these devices may also typically include a wickin fluid communication with the vaporizable material; and a resistiveheating element in fluid contact with the wick and in electrical contactwith the first and second electrical contacts.

In general, applicants have found that, for cartridges having a basethat fits into the rectangular opening of a vaporizer (particularly onethat is between 13-14 mm deep, 4.5-5.5 mm wide, and 13-14 mm long), theit is beneficial to have a length of the base (which is generally theconnection region of the base for interfacing into the rectangularopening) that is greater than 10 mm, however when the base is greaterthan 10 mm (e.g., greater than 11 mm, greater than 12 mm, greater than13 mm), the stability of the cartridge and in particular the electricalcontacts, may be greatly enhanced if the cartridge includes one or more(e.g., two) locking gaps near the bottom surface of the cartridge intowhich a complimentary detent on the vaporizer can couple to. Inparticular, it may be beneficial to have the first and second lockinggaps within 6 mm of the bottom surface, and more specifically within 3-4mm of the bottom surface. The first and second lateral surfaces may beseparated from each other by between 13-14 mm, e.g., they may be on theshort sides of a cartridge base having a rectangular cross-section (arectangular base).

As mentioned, any of these cartridges may include a wick extendingthrough the fluid storage compartment and into the vaporizable material,a resistive heating element in contact with the first and secondelectrical contacts, and a heating chamber in electrical contact withthe first and second electrical contacts.

It may also be beneficial to include one or more (e.g., two) detentsextending from a major surface (e.g., two major surfaces) of the base,such as from a third and/or fourth lateral wall of the base.

The cartridge may include any appropriate vaporizable material, such asa nicotine salt solution.

In general, the mouthpiece may be attached opposite from the base. Thefluid storage compartment may also comprises an air path extending therethrough (e.g., a cannula or tube). In some variations at least part ofthe fluid storage compartment may be within the base. The compartmentmay be transparent (e.g., made from a plastic or polymeric material thatis clear) or opaque, allowing the user to see how much fluid is left.

In general, the locking gap(s) may be a channel in the first lateralsurface (e.g., a channel transversely across the first lateral surfaceparallel to the bottom surface), an opening or hole in the first lateralsurface, and/or a hole in the first lateral surface. The locking gap isgenerally a gap that is surrounded at least on the upper and lower(proximal and distal) sides by the lateral wall to allow the detent onthe vaporizer to engage therewith.

The locking gap may be generally between 0.1 mm and 2 mm wide (e.g.,between a lower value of about 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8,0.9, 1.0, 1.1, 1.2, 1.3, 1.4, etc. and an upper value of about 0.4, 0.5,0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9,2.0, etc., where the upper value is always greater than the lowervalue).

Also described are vaporizers and method of using them with cartridges,including those described herein.

In some variations, the apparatuses described herein may include aninhalable aerosol comprising: an oven comprising an oven chamber and aheater for heating a vapor forming medium in the oven chamber togenerate a vapor; a condenser comprising a condensation chamber in whichat least a fraction of the vapor condenses to form the inhalableaerosol; an air inlet that originates a first airflow path that includesthe oven chamber; and an aeration vent that originates a second airflowpath that allows air from the aeration vent to join the first airflowpath prior to or within the condensation chamber and downstream from theoven chamber thereby forming a joined path, wherein the joined path isconfigured to deliver the inhalable aerosol formed in the condensationchamber to a user.

The oven may be within a body of the device. The device may furthercomprise a mouthpiece, wherein the mouthpiece comprises at least one ofthe air inlet, the aeration vent, and the condenser. The mouthpiece maybe separable from the oven. The mouthpiece may be integral to a body ofthe device, wherein the body comprises the oven. The device may furthercomprise a body that comprises the oven, the condenser, the air inlet,and the aeration vent. The mouthpiece may be separable from the body.

In some variations, the oven chamber may comprise an oven chamber inletand an oven chamber outlet, and the oven further comprises a first valveat the oven chamber inlet, and a second valve at the oven chamberoutlet. The aeration vent may comprise a third valve. The first valve,or said second valve may be chosen from the group of a check valve, aclack valve, a non-return valve, and a one-way valve. The third valvemay be chosen from the group of a check valve, a clack valve, anon-return valve, and a one-way valve. The first or second valve may bemechanically actuated. The first or second valve may be electronicallyactuated. The first valve or second valve may be manually actuated. Thethird valve may be mechanically actuated. The third valve may bemechanically actuated. The third valve may be electronically actuated.The third valve may be manually actuated.

In some variations, the device may further comprise a body thatcomprises at least one of: a power source, a printed circuit board, aswitch, and a temperature regulator. The device may further comprise atemperature regulator in communication with a temperature sensor. Thetemperature sensor may be the heater. The power source may berechargeable. The power source may be removable. The oven may furthercomprise an access lid. The vapor forming medium may comprise tobacco.The vapor forming medium may comprise a botanical. The vapor formingmedium may be heated in the oven chamber wherein the vapor formingmedium may comprise a humectant to produce the vapor, wherein the vaporcomprises a gas phase humectant. The vapor may be mixed in thecondensation chamber with air from the aeration vent to produce theinhalable aerosol comprising particle diameters of average size of about1 micron. The vapor forming medium may be heated in the oven chamber,wherein the vapor is mixed in the condensation chamber with air from theaeration vent to produce the inhalable aerosol comprising particlediameters of average size of less than or equal to 0.9 micron. The vaporforming medium may be heated in the oven chamber, wherein the vapor ismixed in the condensation chamber with air from the aeration vent toproduce the inhalable aerosol comprising particle diameters of averagesize of less than or equal to 0.8 micron. The vapor forming medium maybe heated in the oven chamber, wherein the vapor is mixed in thecondensation chamber with air from the aeration vent to produce theinhalable aerosol comprising particle diameters of average size of lessthan or equal to 0.7 micron. The vapor forming medium may be heated inthe oven chamber, wherein the vapor is mixed in the condensation chamberwith air from the aeration vent to produce the inhalable aerosolcomprising particle diameters of average size of less than or equal to0.6 micron. The vapor forming medium may be heated in the oven chamber,wherein the vapor is mixed in the condensation chamber with air from theaeration vent to produce the inhalable aerosol comprising particlediameters of average size of less than or equal to 0.5 micron.

In some variations, the humectant may comprise glycerol as avapor-forming medium. The humectant may comprise vegetable glycerol. Thehumectant may comprise propylene glycol. The humectant may comprise aratio of vegetable glycerol to propylene glycol. The ratio may be about100:0 vegetable glycerol to propylene glycol. The ratio may be about90:10 vegetable glycerol to propylene glycol. The ratio may be about80:20 vegetable glycerol to propylene glycol. The ratio may be about70:30 vegetable glycerol to propylene glycol. The ratio may be about60:40 vegetable glycerol to propylene glycol. The ratio may be about50:50 vegetable glycerol to propylene glycol. The humectant may comprisea flavorant. The vapor forming medium may be heated to its pyrolytictemperature. The vapor forming medium may heated to 200° C. at most. Thevapor forming medium may be heated to 160° C. at most. The inhalableaerosol may be cooled to a temperature of about 50°-70° C. at most,before exiting the aerosol outlet of the mouthpiece.

Also described herein are methods for generating an inhalable aerosol.Such a method may comprise: providing an inhalable aerosol generatingdevice wherein the device comprises: an oven comprising an oven chamberand a heater for heating a vapor forming medium in the oven chamber andfor forming a vapor therein; a condenser comprising a condensationchamber in which the vapor forms the inhalable aerosol; an air inletthat originates a first airflow path that includes the oven chamber; andan aeration vent that originates a second airflow path that allows airfrom the aeration vent to join the first airflow path prior to or withinthe condensation chamber and downstream from the oven chamber therebyforming a joined path, wherein the joined path is configured to deliverthe inhalable aerosol formed in the condensation chamber to a user.

The oven may be within a body of the device. The device may furthercomprise a mouthpiece, wherein the mouthpiece comprises at least one ofthe air inlet, the aeration vent, and the condenser. The mouthpiece maybe separable from the oven. The mouthpiece may be integral to a body ofthe device, wherein the body comprises the oven. The method may furthercomprise a body that comprises the oven, the condenser, the air inlet,and the aeration vent. The mouthpiece may be separable from the body.

The oven chamber may comprise an oven chamber inlet and an oven chamberoutlet, and the oven further comprises a first valve at the oven chamberinlet, and a second valve at the oven chamber outlet.

The vapor forming medium may comprise tobacco. The vapor forming mediummay comprise a botanical. The vapor forming medium may be heated in theoven chamber wherein the vapor forming medium may comprise a humectantto produce the vapor, wherein the vapor comprises a gas phase humectant.The vapor may comprise particle diameters of average mass of about 1micron. The vapor may comprise particle diameters of average mass ofabout 0.9 micron. The vapor may comprise particle diameters of averagemass of about 0.8 micron. The vapor may comprise particle diameters ofaverage mass of about 0.7 micron. The vapor may comprise particlediameters of average mass of about 0.6 micron. The vapor may compriseparticle diameters of average mass of about 0.5 micron.

In some variations, the humectant may comprise glycerol as avapor-forming medium. The humectant may comprise vegetable glycerol. Thehumectant may comprise propylene glycol. The humectant may comprise aratio of vegetable glycerol to propylene glycol. The ratio may be about100:0 vegetable glycerol to propylene glycol. The ratio may be about90:10 vegetable glycerol to propylene glycol. The ratio may be about80:20 vegetable glycerol to propylene glycol. The ratio may be about70:30 vegetable glycerol to propylene glycol. The ratio may be about60:40 vegetable glycerol to propylene glycol. The ratio may be about50:50 vegetable glycerol to propylene glycol. The humectant may comprisea flavorant. The vapor forming medium may be heated to its pyrolytictemperature. The vapor forming medium may heated to 200° C. at most. Thevapor forming medium may be heated to 160° C. at most. The inhalableaerosol may be cooled to a temperature of about 50°-70° C. at most,before exiting the aerosol outlet of the mouthpiece.

The device may be user serviceable. The device may not be userserviceable.

A method for generating an inhalable aerosol may include: providing avaporization device, wherein said device produces a vapor comprisingparticle diameters of average mass of about 1 micron or less, whereinsaid vapor is formed by heating a vapor forming medium in an ovenchamber to a first temperature below the pyrolytic temperature of saidvapor forming medium, and cooling said vapor in a condensation chamberto a second temperature below the first temperature, before exiting anaerosol outlet of said device.

A method of manufacturing a device for generating an inhalable aerosolmay include: providing said device comprising a mouthpiece comprising anaerosol outlet at a first end of the device; an oven comprising an ovenchamber and a heater for heating a vapor forming medium in the ovenchamber and for forming a vapor therein, a condenser comprising acondensation chamber in which the vapor forms the inhalable aerosol, anair inlet that originates a first airflow path that includes the ovenchamber and then the condensation chamber, an aeration vent thatoriginates a second airflow path that joins the first airflow path priorto or within the condensation chamber after the vapor is formed in theoven chamber, wherein the joined first airflow path and second airflowpath are configured to deliver the inhalable aerosol formed in thecondensation chamber through the aerosol outlet of the mouthpiece to auser.

The method may further comprise providing the device comprising a powersource or battery, a printed circuit board, a temperature regulator oroperational switches.

A device for generating an inhalable aerosol may comprise a mouthpiececomprising an aerosol outlet at a first end of the device and an airinlet that originates a first airflow path; an oven comprising an ovenchamber that is in the first airflow path and includes the oven chamberand a heater for heating a vapor forming medium in the oven chamber andfor forming a vapor therein; a condenser comprising a condensationchamber in which the vapor forms the inhalable aerosol; and an aerationvent that originates a second airflow path that allows air from theaeration vent to join the first airflow path prior to or within thecondensation chamber and downstream from the oven chamber therebyforming a joined path, wherein the joined path is configured to deliverthe inhalable aerosol formed in the condensation chamber through theaerosol outlet of the mouthpiece to a user.

Also described herein are vaporization devices and methods of operatingthem. In particular, described herein are methods for controlling thetemperature of a resistive heater (e.g., resistive heating element) bycontrolling the power applied to a resistive heater of a vaporizationdevice by measuring the resistance of the resistive heater at discreteintervals before (e.g., baseline or ambient temperature) and duringvaporization (e.g., during heating to vaporize a material within thedevice). Changes in the resistance during heating may be linearlyrelated to the temperature of the resistive heater over the operationalrange, and therefore may be used to control the power applied to heatthe resistive heater during operation. Also described herein arevaporization devices that are configured to measure the resistance ofthe resistive heater during heating (e.g., during a pause in theapplication of power to heat the resistive heater) and to control theapplication of power to the resistive heater based on the resistancevalues.

In general, in any of the methods and apparatuses described herein, thecontrol circuitry (which may include one or more circuits, amicrocontroller, and/or control logic) may compare a resistance of theresistive heater during heating, e.g., following a sensor inputindicating that a user wishes to withdraw vapor, to a target resistanceof the heating element. The target resistance is typically theresistance of the resistive heater at a desired (and in some casesestimated) target vaporization temperature. The apparatus and methodsmay be configured to offer multiple and/or adjustable vaporizationtemperatures.

In some variations, the target resistance is an approximation orestimate of the resistance of the resistive heater when the resistiveheater is heated to the target temperature (or temperature ranges). Insome variations, the target reference is based on a baseline resistancefor the resistive heater and/or the percent change in resistance frombaseline resistance for the resistive heater at a target temperature. Ingeneral, the baseline resistance may be referred to as the resistance ofthe resistive heater at an ambient temperature.

For example, a method of controlling a vaporization device may include:placing a vaporizable material in thermal contact with a resistiveheater; applying power to the resistive heater to heat the vaporizablematerial; measuring the resistance of the resistive heater; andadjusting the applied power to the resistive heater based on thedifference between the resistance of the resistive heater and a targetresistance of the heating element.

In some variations, the target resistance is based on a referenceresistance. For example, the reference resistance may be approximatelythe resistance of the coil at target temperature. This referenceresistance may be calculated, estimated or approximated (as describedherein) or it may be determined empirically based on the resistancevalues of the resistive heater at one or more target temperatures.

In some variations, the target resistance is based on the resistance ofthe resistive heater at an ambient temperature. For example, the targetresistance may be estimated based on the electrical properties of theresistive heater, e.g., the temperature coefficient of resistance orTCR, of the resistive heater (e.g., “resistive heating element” or“vaporizing element”).

For example, a vaporization device (e.g., an electronic vaporizerdevice) may include a puff sensor, a power source (e.g., battery,capacitor, etc.), a heating element controller (e.g., microcontroller),and a resistive heater. A separate temperature sensor may also beincluded to determine an actual temperature of ambient temperatureand/or the resistive heater, or a temperature sensor may be part of theheating element controller. However, in general, the microcontroller maycontrol the temperature of the resistive heater (e.g., resistive coil,etc.) based on a change in resistance due to temperature (e.g., TCR).

In general, the heater may be any appropriate resistive heater, such asa resistive coil. The heater is typically coupled to the heatercontroller so that the heater controller applies power (e.g., from thepower source) to the heater. The heater controller may includeregulatory control logic to regulate the temperature of the heater byadjusting the applied power. The heater controller may include adedicated or general-purpose processor, circuitry, or the like and isgenerally connected to the power source and may receive input from thepower source to regulate the applied power to the heater.

For example, any of these apparatuses may include logic for determiningthe temperature of the heater based on the TCR. The resistance of theheater (e.g., a resistive heater) may be measured (R_(heater)) duringoperation of the apparatus and compared to a target resistance, which istypically the resistance of the resistive heater at the targettemperature. In some cases this resistance may be estimated from theresistance of the resistive hearing element at ambient temperature(baseline).

In some variations, a reference resistor (R_(reference)) may be used toset the target resistance. The ratio of the heater resistance to thereference resistance (R_(heater)/R_(reference)) is linearly related tothe temperature (above room temp) of the heater, and may be directlyconverted to a calibrated temperature. For example, a change intemperature of the heater relative to room temperature may be calculatedusing an expression such as (R_(heater)/R_(reference)−1)*(1/TCR), whereTCR is the temperature coefficient of resistivity for the heater. In oneexample, TCR for a particular device heater is 0.00014/° C. Indetermining the partial doses and doses described herein, thetemperature value used (e.g., the temperature of the vaporizablematerial during a dose interval, T1, described in more detail below) mayrefer to the unitless resistive ratio (e.g., R_(heater)/R_(refrerence))or it may refer to the normalized/corrected temperature (e.g., in ° C.).

When controlling a vaporization device by comparing a measure resistanceof a resistive heater to a target resistance, the target resistance maybe initially calculated and may be factory preset and/or calibrated by auser-initiated event. For example, the target resistance of theresistive heater during operation of the apparatus may be set by thepercent change in baseline resistance plus the baseline resistance ofthe resistive heater, as will be described in more detail below. Asmentioned, the resistance of the heating element at ambient is thebaseline resistance. For example, the target resistance may be based onthe resistance of the resistive heater at an ambient temperature and atarget change in temperature of the resistive heater.

As mentioned above, the target resistance of the resistive heater may bebased on a target heating element temperature. Any of the apparatusesand methods for using them herein may include determining the targetresistance of the resistive heater based on a resistance of theresistive heater at ambient temperature and a percent change in aresistance of the resistive heater at an ambient temperature.

In any of the methods and apparatuses described herein, the resistanceof the resistive heater may be measured (using a resistive measurementcircuit) and compared to a target resistance by using a voltage divider.Alternatively or additionally any of the methods and apparatusesdescribed herein may compare a measured resistance of the resistiveheater to a target resistance using a Wheatstone bridge and therebyadjust the power to increase/decrease the applied power based on thiscomparison.

In any of the variations described herein, adjusting the applied powerto the resistive heater may comprise comparing the resistance (actualresistance) of the resistive heater to a target resistance using avoltage divider, Wheatstone bridge, amplified Wheatstone bridge, or RCcharge time circuit.

As mentioned above, a target resistance of the resistive heater andtherefore target temperature may be determined using a baselineresistance measurement taken from the resistive heater. The apparatusand/or method may approximate a baseline resistance for the resistiveheater by waiting an appropriate length of time (e.g., 1 second, 10seconds, 30 seconds, 1 minute, 1.5 minutes, 2 minutes, 3 minutes, 4minutes, 5 minutes, 6 minutes, 7 minutes, 8 minutes, 9 minutes, 10minutes, 11 minutes, 12 minutes, 15 minutes, 20 minutes, etc.) from thelast application of energy to the resistive heater to measure aresistance (or series of resistance that may be averaged, etc.)representing the baseline resistance for the resistive heater. In somevariations a plurality of measurements made when heating/applying powerto the resistive heater is prevented may be analyzed by the apparatus todetermine when the resistance values do not vary outside of apredetermined range (e.g., when the resistive heater has ‘cooled’ down,and therefore the resistance is no longer changing due to temperaturedecreasing/increasing), for example, when the rate of change of theresistance of the heating element over time is below some stabilitythreshold.

For example, any of the methods and apparatuses described herein maymeasure the resistance of the resistive heater an ambient temperature bymeasuring the resistance of the resistive heater after a predeterminedtime since power was last applied to the resistive heater. As mentionedabove, the predetermined time period may be seconds, minutes, etc.

In any of these variations the baseline resistance may be stored in along-term memory (including volatile, non-volatile or semi-volatilememory). Storing a baseline resistance (“the resistance of the resistiveheater an ambient temperature”) may be done periodically (e.g., once per2 minute, 5 minutes, 10 minutes, 1 hour, etc., or every time aparticular event occurs, such as loading vaporizable material), or oncefor a single time.

Any of these methods may also include calculating an absolute targetcoil temperature from an actual device temperature. As mentioned, above,based on the material properties of the resistive heater (e.g., coil)the resistance and/or change in resistance over time may be usedcalculate an actual temperature, which may be presented to a user, e.g.,on the face of the device, or communicated to an “app” or other outputtype.

In any of the methods and apparatuses described herein, the apparatusmay detect the resistance of the resistive heater only when power is notbeing applied to the resistive heater while detecting the resistance;once the resistance detection is complete, power may again be applied(and this application may be modified by the control logic describedherein). For example, in any of these devices and methods the resistanceof the resistive heater may be measured only when suspending theapplication of power to the resistive heater.

For example, a method of controlling a vaporization device may include:placing a vaporizable material in thermal contact with a resistiveheater; applying power to the resistive heater to heat the vaporizablematerial; suspending the application of power to the resistive heaterwhile measuring the resistance of the resistive heater; and adjustingthe applied power to the resistive heater based on the differencebetween the resistance of the heating element and a target resistance ofthe resistive heater, wherein measuring the resistance of the resistiveheater comprises measuring the resistance using a voltage divider,Wheatstone bridge, amplified Wheatstone bridge, or RC charge timecircuit.

For example, a vaporization device may include: a microcontroller; areservoir configured to hold a vaporizable material; a resistive heaterconfigured to thermally contact the vaporizable material from thereservoir; a resistance measurement circuit connected to themicrocontroller configured to measure the resistance of the resistiveheater; and a power source, wherein the microcontroller applies powerfrom the power source to heat the resistive heater and adjusts theapplied power based on the difference between the resistance of theresistive heater and a target resistance of the resistive heater.

A vaporization device may include: a microcontroller; a reservoirconfigured to hold a vaporizable material; a resistive heater configuredto thermally contact the vaporizable material from the reservoir; aresistance measurement circuit connected to the microcontrollerconfigured to measure the resistance of the resistive heater; a powersource; and a sensor having an output connected to the microcontroller,wherein the microcontroller is configured to determine when theresistive heater applies power from the power source to heat theresistive heater; a target resistance circuit configured to determine atarget resistance, the target resistance circuit comprising one of: avoltage divider, a Wheatstone bridge, an amplified Wheatstone bridge, oran RC charge time circuit, wherein the microcontroller applies powerfrom the power source to heat the resistive heater and adjusts theapplied power based on the difference between the resistance of theresistive heater and the target resistance of the resistive heater.

In any of the methods and apparatuses (e.g., devices and systems)described herein, the apparatus may be configured to be triggered by auser drawing on or otherwise indicating that they would like to beginvaporization of the vaporizing material. This user-initiated start maybe detected by a sensor, such as a pressure sensor (“puff sensor”)configured to detect draw. The sensor may generally have an output thatis connected to the controller (e.g., microcontroller), and themicrocontroller may be configured to determine when the resistive heaterapplies power from the power source to heat the resistive heater.

For example, a vaporizing device as described herein may include apressure sensor having an output connected to the microcontroller,wherein the microcontroller is configured to determine when theresistive heater applies power from the power source to heat theresistive heater.

In general, any of the apparatuses described herein may be adapted toperform any of the methods described herein, including determining if aninstantaneous (ongoing) resistance measurement of the resistive heateris above/below and/or within a tolerable range of a target resistance.Any of these apparatuses may also determine the target resistance. Asmentioned, this may be determined empirically and set to a resistancevalue, and/or it may be calculated. For example, any of theseapparatuses (e.g., devices) may include a target resistance circuitconfigured to determine the target resistance, the target resistancecircuit comprising one of: a voltage divider, a Wheatstone bridge, anamplified Wheatstone bridge, or an RC charge time circuit. Alternativelyor additionally, a voltage divider, a Wheatstone bridge, an amplifiedWheatstone bridge, or an RC charge time circuit may be included as partof the microcontroller or other circuitry that compares the measuredresistance of the resistive heater to a target resistance.

For example, a target resistance circuit may be configured to determinethe target resistance and/or compare the measured resistance of theresistive heater to the target resistance. The target resistance circuitcomprising a voltage divider having a reference resistance equivalent tothe target resistance. A target resistance circuit may be configured todetermine the target resistance, the target resistance circuitcomprising a Wheatstone bridge, wherein the target resistance iscalculated by adding a resistance of the resistive heater at an ambienttemperature and a target change in temperature of the resistive heater.

As mentioned, any of these apparatuses may include a memory configuredto store a resistance of the resistive heater at an ambient temperature.Further, any of these apparatuses may include a temperature inputcoupled to the microcontroller and configured to provide an actualdevice temperature. The device temperature may be sensed and/or providedby any appropriate sensor, including thermistor, thermocouple, resistivetemperature sensor, silicone bandgap temperature sensor, etc. Themeasured device temperature may be used to calculate a target resistancethat corresponds to a certain resistive heater (e.g., coil) temperature.In some variations the apparatus may display and/or output an anestimate of the temperature of the resistive heater. The apparatus mayinclude a display or may communicate (e.g., wirelessly) with anotherapparatus that receives the temperature or resistance values.

The devices described herein may include an inhalable aerosolcomprising: an oven comprising an oven chamber and a heater for heatinga vapor forming medium in the oven chamber to generate a vapor; acondenser comprising a condensation chamber in which at least a fractionof the vapor condenses to form the inhalable aerosol; an air inlet thatoriginates a first airflow path that includes the oven chamber; and anaeration vent that originates a second airflow path that allows air fromthe aeration vent to join the first airflow path prior to or within thecondensation chamber and downstream from the oven chamber therebyforming a joined path, wherein the joined path is configured to deliverthe inhalable aerosol formed in the condensation chamber to a user.

In any of these variations the oven is within a body of the device. Thedevice may further comprise a mouthpiece, wherein the mouthpiececomprises at least one of the air inlet, the aeration vent, and thecondenser. The mouthpiece may be separable from the oven. The mouthpiecemay be integral to a body of the device, wherein the body comprises theoven. The device may further comprise a body that comprises the oven,the condenser, the air inlet, and the aeration vent. The mouthpiece maybe separable from the body.

In some variations, the oven chamber may comprise an oven chamber inletand an oven chamber outlet, and the oven further comprises a first valveat the oven chamber inlet, and a second valve at the oven chamberoutlet. The aeration vent may comprise a third valve. The first valve,or said second valve may be chosen from the group of a check valve, aclack valve, a non-return valve, and a one-way valve. The third valvemay be chosen from the group of a check valve, a clack valve, anon-return valve, and a one-way valve. The first or second valve may bemechanically actuated. The first or second valve may be electronicallyactuated. The first valve or second valve may be manually actuated. Thethird valve may be mechanically actuated. The third valve may bemechanically actuated. The third valve may be electronically actuated.The third valve may be manually actuated.

In any of these variations, the device may further comprise a body thatcomprises at least one of: a power source, a printed circuit board, aswitch, and a temperature regulator. The device may further comprise atemperature regulator in communication with a temperature sensor. Thetemperature sensor may be the heater. The power source may berechargeable. The power source may be removable. The oven may furthercomprise an access lid. The vapor forming medium may comprise tobacco.The vapor forming medium may comprise a botanical. The vapor formingmedium may be heated in the oven chamber wherein the vapor formingmedium may comprise a humectant to produce the vapor, wherein the vaporcomprises a gas phase humectant. The vapor may be mixed in thecondensation chamber with air from the aeration vent to produce theinhalable aerosol comprising particle diameters of average size of about1 micron. The vapor forming medium may be heated in the oven chamber,wherein the vapor is mixed in the condensation chamber with air from theaeration vent to produce the inhalable aerosol comprising particlediameters of average size of less than or equal to 0.9 micron. The vaporforming medium may be heated in the oven chamber, wherein the vapor ismixed in the condensation chamber with air from the aeration vent toproduce the inhalable aerosol comprising particle diameters of averagesize of less than or equal to 0.8 micron. The vapor forming medium maybe heated in the oven chamber, wherein the vapor is mixed in thecondensation chamber with air from the aeration vent to produce theinhalable aerosol comprising particle diameters of average size of lessthan or equal to 0.7 micron. The vapor forming medium may be heated inthe oven chamber, wherein the vapor is mixed in the condensation chamberwith air from the aeration vent to produce the inhalable aerosolcomprising particle diameters of average size of less than or equal to0.6 micron. The vapor forming medium may be heated in the oven chamber,wherein the vapor is mixed in the condensation chamber with air from theaeration vent to produce the inhalable aerosol comprising particlediameters of average size of less than or equal to 0.5 micron.

In any of these variations, the humectant may comprise glycerol as avapor-forming medium. The humectant may comprise vegetable glycerol. Thehumectant may comprise propylene glycol. The humectant may comprise aratio of vegetable glycerol to propylene glycol. The ratio may be about100:0 vegetable glycerol to propylene glycol. The ratio may be about90:10 vegetable glycerol to propylene glycol. The ratio may be about80:20 vegetable glycerol to propylene glycol. The ratio may be about70:30 vegetable glycerol to propylene glycol. The ratio may be about60:40 vegetable glycerol to propylene glycol. The ratio may be about50:50 vegetable glycerol to propylene glycol. The humectant may comprisea flavorant. The vapor forming medium may be heated to its pyrolytictemperature. The vapor forming medium may heated to 200° C. at most. Thevapor forming medium may be heated to 160° C. at most. The inhalableaerosol may be cooled to a temperature of about 50°-70° C. at most,before exiting the aerosol outlet of the mouthpiece.

In any of these variations, the method comprises A method for generatingan inhalable aerosol, the method comprising: providing an inhalableaerosol generating device wherein the device comprises: an ovencomprising an oven chamber and a heater for heating a vapor formingmedium in the oven chamber and for forming a vapor therein; a condensercomprising a condensation chamber in which the vapor forms the inhalableaerosol; an air inlet that originates a first airflow path that includesthe oven chamber; and an aeration vent that originates a second airflowpath that allows air from the aeration vent to join the first airflowpath prior to or within the condensation chamber and downstream from theoven chamber thereby forming a joined path, wherein the joined path isconfigured to deliver the inhalable aerosol formed in the condensationchamber to a user.

In any of these variations the oven is within a body of the device. Thedevice may further comprise a mouthpiece, wherein the mouthpiececomprises at least one of the air inlet, the aeration vent, and thecondenser. The mouthpiece may be separable from the oven. The mouthpiecemay be integral to a body of the device, wherein the body comprises theoven. The method may further comprise a body that comprises the oven,the condenser, the air inlet, and the aeration vent. The mouthpiece maybe separable from the body.

In any of these variations, the oven chamber may comprise an ovenchamber inlet and an oven chamber outlet, and the oven further comprisesa first valve at the oven chamber inlet, and a second valve at the ovenchamber outlet.

The vapor forming medium may comprise tobacco. The vapor forming mediummay comprise a botanical. The vapor forming medium may be heated in theoven chamber wherein the vapor forming medium may comprise a humectantto produce the vapor, wherein the vapor comprises a gas phase humectant.The vapor may comprise particle diameters of average mass of about 1micron. The vapor may comprise particle diameters of average mass ofabout 0.9 micron. The vapor may comprise particle diameters of averagemass of about 0.8 micron. The vapor may comprise particle diameters ofaverage mass of about 0.7 micron. The vapor may comprise particlediameters of average mass of about 0.6 micron. The vapor may compriseparticle diameters of average mass of about 0.5 micron.

In any of these variations, the humectant may comprise glycerol as avapor-forming medium. The humectant may comprise vegetable glycerol. Thehumectant may comprise propylene glycol. The humectant may comprise aratio of vegetable glycerol to propylene glycol. The ratio may be about100:0 vegetable glycerol to propylene glycol. The ratio may be about90:10 vegetable glycerol to propylene glycol. The ratio may be about80:20 vegetable glycerol to propylene glycol. The ratio may be about70:30 vegetable glycerol to propylene glycol. The ratio may be about60:40 vegetable glycerol to propylene glycol. The ratio may be about50:50 vegetable glycerol to propylene glycol. The humectant may comprisea flavorant. The vapor forming medium may be heated to its pyrolytictemperature. The vapor forming medium may heated to 200° C. at most. Thevapor forming medium may be heated to 160° C. at most. The inhalableaerosol may be cooled to a temperature of about 50°-70° C. at most,before exiting the aerosol outlet of the mouthpiece.

In any of these variations, the device may be user serviceable. Thedevice may not be user serviceable.

In any of these variations, a method for generating an inhalableaerosol, the method comprising: providing a vaporization device, whereinsaid device produces a vapor comprising particle diameters of averagemass of about 1 micron or less, wherein said vapor is formed by heatinga vapor forming medium in an oven chamber to a first temperature belowthe pyrolytic temperature of said vapor forming medium, and cooling saidvapor in a condensation chamber to a second temperature below the firsttemperature, before exiting an aerosol outlet of said device.

In any of these variations, a method of manufacturing a device forgenerating an inhalable aerosol comprising: providing said devicecomprising a mouthpiece comprising an aerosol outlet at a first end ofthe device; an oven comprising an oven chamber and a heater for heatinga vapor forming medium in the oven chamber and for forming a vaportherein, a condenser comprising a condensation chamber in which thevapor forms the inhalable aerosol, an air inlet that originates a firstairflow path that includes the oven chamber and then the condensationchamber, an aeration vent that originates a second airflow path thatjoins the first airflow path prior to or within the condensation chamberafter the vapor is formed in the oven chamber, wherein the joined firstairflow path and second airflow path are configured to deliver theinhalable aerosol formed in the condensation chamber through the aerosoloutlet of the mouthpiece to a user.

The method may further comprise providing the device comprising a powersource or battery, a printed circuit board, a temperature regulator oroperational switches.

In any of these variations a device for generating an inhalable aerosolmay comprise a mouthpiece comprising an aerosol outlet at a first end ofthe device and an air inlet that originates a first airflow path; anoven comprising an oven chamber that is in the first airflow path andincludes the oven chamber and a heater for heating a vapor formingmedium in the oven chamber and for forming a vapor therein; a condensercomprising a condensation chamber in which the vapor forms the inhalableaerosol; and an aeration vent that originates a second airflow path thatallows air from the aeration vent to join the first airflow path priorto or within the condensation chamber and downstream from the ovenchamber thereby forming a joined path, wherein the joined path isconfigured to deliver the inhalable aerosol formed in the condensationchamber through the aerosol outlet of the mouthpiece to a user.

In any of these variations a device for generating an inhalable aerosolmay comprise: a mouthpiece comprising an aerosol outlet at a first endof the device, an air inlet that originates a first airflow path, and anaeration vent that originates a second airflow path that allows air fromthe aeration vent to join the first airflow path; an oven comprising anoven chamber that is in the first airflow path and includes the ovenchamber and a heater for heating a vapor forming medium in the ovenchamber and for forming a vapor therein; and a condenser comprising acondensation chamber in which the vapor forms the inhalable aerosol andwherein air from the aeration vent joins the first airflow path prior toor within the condensation chamber and downstream from the oven chamberthereby forming a joined path, wherein the joined path is configured todeliver the inhalable aerosol through the aerosol outlet of themouthpiece to a user.

In any of these variations, a device for generating an inhalable aerosolmay comprise: a device body comprising a cartridge receptacle; acartridge comprising: a fluid storage compartment, and a channelintegral to an exterior surface of the cartridge, and an air inletpassage formed by the channel and an internal surface of the cartridgereceptacle when the cartridge is inserted into the cartridge receptacle;wherein the channel forms a first side of the air inlet passage, and aninternal surface of the cartridge receptacle forms a second side of theair inlet passage.

In any of these variations, a device for generating an inhalable aerosolmay comprise: a device body comprising a cartridge receptacle; acartridge comprising: a fluid storage compartment, and a channelintegral to an exterior surface of the cartridge, and an air inletpassage formed by the channel and an internal surface of the cartridgereceptacle when the cartridge is inserted into the cartridge receptacle;wherein the channel forms a first side of the air inlet passage, and aninternal surface of the cartridge receptacle forms a second side of theair inlet passage.

In any of these variations the channel may comprise at least one of agroove, a trough, a depression, a dent, a furrow, a trench, a crease,and a gutter. The integral channel may comprise walls that are eitherrecessed into the surface or protrude from the surface where it isformed. The internal side walls of the channel may form additional sidesof the air inlet passage. The cartridge may further comprise a secondair passage in fluid communication with the air inlet passage to thefluid storage compartment, wherein the second air passage is formedthrough the material of the cartridge. The cartridge may furthercomprise a heater. The heater may be attached to a first end of thecartridge.

In any of these variations the heater may comprise a heater chamber, afirst pair of heater contacts, a fluid wick, and a resistive heatingelement in contact with the wick, wherein the first pair of heatercontacts comprise thin plates affixed about the sides of the heaterchamber, and wherein the fluid wick and resistive heating element aresuspended therebetween. The first pair of heater contacts may furthercomprise a formed shape that comprises a tab having a flexible springvalue that extends out of the heater to couple to complete a circuitwith the device body. The first pair of heater contacts may be a heatsink that absorbs and dissipates excessive heat produced by theresistive heating element. The first pair of heater contacts may contacta heat shield that protects the heater chamber from excessive heatproduced by the resistive heating element. The first pair of heatercontacts may be press-fit to an attachment feature on the exterior wallof the first end of the cartridge. The heater may enclose a first end ofthe cartridge and a first end of the fluid storage compartment. Theheater may comprise a first condensation chamber. The heater maycomprise more than one first condensation chamber. The firstcondensation chamber may be formed along an exterior wall of thecartridge. The cartridge may further comprise a mouthpiece. Themouthpiece may be attached to a second end of the cartridge. Themouthpiece may comprise a second condensation chamber. The mouthpiecemay comprise more than one second condensation chamber. The secondcondensation chamber may be formed along an exterior wall of thecartridge.

In any of these variations the cartridge may comprise a firstcondensation chamber and a second condensation chamber. The firstcondensation chamber and the second condensation chamber may be in fluidcommunication. The mouthpiece may comprise an aerosol outlet in fluidcommunication with the second condensation chamber. The mouthpiece maycomprise more than one aerosol outlet in fluid communication with morethan one the second condensation chamber. The mouthpiece may enclose asecond end of the cartridge and a second end of the fluid storagecompartment.

In any of these variations, the device may comprise an airflow pathcomprising an air inlet passage, a second air passage, a heater chamber,a first condensation chamber, a second condensation chamber, and anaerosol outlet. The airflow path may comprise more than one air inletpassage, a heater chamber, more than one first condensation chamber,more than one second condensation chamber, more than one secondcondensation chamber, and more than one aerosol outlet. The heater maybe in fluid communication with the fluid storage compartment. The fluidstorage compartment may be capable of retaining condensed aerosol fluid.The condensed aerosol fluid may comprise a nicotine formulation. Thecondensed aerosol fluid may comprise a humectant. The humectant maycomprise propylene glycol. The humectant may comprise vegetableglycerin.

In any of these variations the cartridge may be detachable. In any ofthese variations the cartridge may be receptacle and the detachablecartridge form a separable coupling. The separable coupling may comprisea friction assembly, a snap-fit assembly or a magnetic assembly. Thecartridge may comprise a fluid storage compartment, a heater affixed toa first end with a snap-fit coupling, and a mouthpiece affixed to asecond end with a snap-fit coupling.

In any of these variations, a device for generating an inhalable aerosolmay comprise: a device body comprising a cartridge receptacle forreceiving a cartridge; wherein an interior surface of the cartridgereceptacle forms a first side of an air inlet passage when a cartridgecomprising a channel integral to an exterior surface is inserted intothe cartridge receptacle, and wherein the channel forms a second side ofthe air inlet passage.

In any of these variations, a device for generating an inhalable aerosolmay comprise: a device body comprising a cartridge receptacle forreceiving a cartridge; wherein the cartridge receptacle comprises achannel integral to an interior surface and forms a first side of an airinlet passage when a cartridge is inserted into the cartridgereceptacle, and wherein an exterior surface of the cartridge forms asecond side of the air inlet passage.

In any of these variations, A cartridge for a device for generating aninhalable aerosol comprising: a fluid storage compartment; a channelintegral to an exterior surface, wherein the channel forms a first sideof an air inlet passage; and wherein an internal surface of a cartridgereceptacle in the device forms a second side of the air inlet passagewhen the cartridge is inserted into the cartridge receptacle.

In any of these variations, a cartridge for a device for generating aninhalable aerosol may comprise: a fluid storage compartment, wherein anexterior surface of the cartridge forms a first side of an air inletchannel when inserted into a device body comprising a cartridgereceptacle, and wherein the cartridge receptacle further comprises achannel integral to an interior surface, and wherein the channel forms asecond side of the air inlet passage.

The cartridge may further comprise a second air passage in fluidcommunication with the channel, wherein the second air passage is formedthrough the material of the cartridge from an exterior surface of thecartridge to the fluid storage compartment.

The cartridge may comprise at least one of: a groove, a trough, adepression, a dent, a furrow, a trench, a crease, and a gutter. Theintegral channel may comprise walls that are either recessed into thesurface or protrude from the surface where it is formed. The internalside walls of the channel may form additional sides of the air inletpassage.

In any of these variations, a device for generating an inhalable aerosolmay comprise: a cartridge comprising; a fluid storage compartment; aheater affixed to a first end comprising; a first heater contact, aresistive heating element affixed to the first heater contact; a devicebody comprising; a cartridge receptacle for receiving the cartridge; asecond heater contact adapted to receive the first heater contact and tocomplete a circuit; a power source connected to the second heatercontact; a printed circuit board (PCB) connected to the power source andthe second heater contact; wherein the PCB is configured to detect theabsence of fluid based on the measured resistance of the resistiveheating element, and turn off the device.

The printed circuit board (PCB) may comprise a microcontroller;switches; circuitry comprising a reference resister; and an algorithmcomprising logic for control parameters; wherein the microcontrollercycles the switches at fixed intervals to measure the resistance of theresistive heating element relative to the reference resistor, andapplies the algorithm control parameters to control the temperature ofthe resistive heating element.

The micro-controller may instruct the device to turn itself off when theresistance exceeds the control parameter threshold indicating that theresistive heating element is dry.

In any of these variations, a cartridge for a device for generating aninhalable aerosol may comprise: a fluid storage compartment; a heateraffixed to a first end comprising: a heater chamber, a first pair ofheater contacts, a fluid wick, and a resistive heating element incontact with the wick; wherein the first pair of heater contactscomprise thin plates affixed about the sides of the heater chamber, andwherein the fluid wick and resistive heating element are suspendedtherebetween.

The first pair of heater contacts may further comprise: a formed shapethat comprises a tab having a flexible spring value that extends out ofthe heater to complete a circuit with the device body. The heatercontacts may be configured to mate with a second pair of heater contactsin a cartridge receptacle of the device body to complete a circuit. Thefirst pair of heater contacts may also be a heat sink that absorbs anddissipates excessive heat produced by the resistive heating element. Thefirst pair of heater contacts may be a heat shield that protects theheater chamber from excessive heat produced by the resistive heatingelement.

In any of these variations, a cartridge for a device for generating aninhalable aerosol may comprise: a heater comprising; a heater chamber, apair of thin plate heater contacts therein, a fluid wick positionedbetween the heater contacts, and a resistive heating element in contactwith the wick; wherein the heater contacts each comprise a fixation sitewherein the resistive heating element is tensioned therebetween.

In any of these variations, a cartridge for a device for generating aninhalable aerosol may comprise a heater, wherein the heater is attachedto a first end of the cartridge.

The heater may enclose a first end of the cartridge and a first end ofthe fluid storage compartment. The heater may comprise more than onefirst condensation chamber. The heater may comprise a first condensationchamber. The condensation chamber may be formed along an exterior wallof the cartridge.

In any of these variations, a cartridge for a device for generating aninhalable aerosol may comprise a fluid storage compartment; and amouthpiece, wherein the mouthpiece is attached to a second end of thecartridge.

The mouthpiece may enclose a second end of the cartridge and a secondend of the fluid storage compartment. The mouthpiece may comprise asecond condensation chamber. The mouthpiece may comprise more than onesecond condensation chamber. The second condensation chamber may beformed along an exterior wall of the cartridge.

In any of these variations, a cartridge for a device for generating aninhalable aerosol may comprise: a fluid storage compartment; a heateraffixed to a first end; and a mouthpiece affixed to a second end;wherein the heater comprises a first condensation chamber and themouthpiece comprises a second condensation chamber.

The heater may comprise more than one first condensation chamber and themouthpiece comprises more than one second condensation chamber. Thefirst condensation chamber and the second condensation chamber may be influid communication. The mouthpiece may comprise an aerosol outlet influid communication with the second condensation chamber. The mouthpiecemay comprise two to more aerosol outlets. The cartridge may meet ISOrecycling standards. The cartridge may meet ISO recycling standards forplastic waste.

In any of these variations, a device for generating an inhalable aerosolmay comprise: a device body comprising a cartridge receptacle; and adetachable cartridge; wherein the cartridge receptacle and thedetachable cartridge form a separable coupling, wherein the separablecoupling comprises a friction assembly, a snap-fit assembly or amagnetic assembly.

In any of these variations, a method of fabricating a device forgenerating an inhalable aerosol may comprise: providing a device bodycomprising a cartridge receptacle; and providing a detachable cartridge;wherein the cartridge receptacle and the detachable cartridge form aseparable coupling comprising a friction assembly, a snap-fit assemblyor a magnetic assembly.

In any of these variations, a method of fabricating a cartridge for adevice for generating an inhalable aerosol may comprise: providing afluid storage compartment; affixing a heater to a first end with asnap-fit coupling; and affixing a mouthpiece to a second end with asnap-fit coupling.

In any of these variations A cartridge for a device for generating aninhalable aerosol with an airflow path comprising: a channel comprisinga portion of an air inlet passage; a second air passage in fluidcommunication with the channel; a heater chamber in fluid communicationwith the second air passage; a first condensation chamber in fluidcommunication with the heater chamber; a second condensation chamber influid communication with the first condensation chamber; and an aerosoloutlet in fluid communication with second condensation chamber.

In any of these variations, a cartridge for a device for generating aninhalable aerosol may comprise: a fluid storage compartment; a heateraffixed to a first end; and a mouthpiece affixed to a second end;wherein said mouthpiece comprises two or more aerosol outlets.

In any of these variations, a system for providing power to anelectronic device for generating an inhalable vapor, the system maycomprise; a rechargeable power storage device housed within theelectronic device for generating an inhalable vapor; two or more pinsthat are accessible from an exterior surface of the electronic devicefor generating an inhalable vapor, wherein the charging pins are inelectrical communication with the rechargeable power storage device; acharging cradle comprising two or more charging contacts configured toprovided power to the rechargeable storage device, wherein the devicecharging pins are reversible such that the device is charged in thecharging cradle for charging with a first charging pin on the device incontact a first charging contact on the charging cradle and a secondcharging pin on the device in contact with second charging contact onthe charging cradle and with the first charging pin on the device incontact with second charging contact on the charging cradle and thesecond charging pin on the device in contact with the first chargingcontact on the charging cradle.

The charging pins may be visible on an exterior housing of the device.The user may permanently disable the device by opening the housing. Theuser may permanently destroy the device by opening the housing.

Additional aspects and advantages of the present disclosure will becomereadily apparent to those skilled in this art from the followingdetailed description, wherein only illustrative embodiments of thepresent disclosure are shown and described. As will be realized, thepresent disclosure is capable of other and different embodiments, andits several details are capable of modifications in various obviousrespects, all without departing from the disclosure. Accordingly, thedrawings and description are to be regarded as illustrative in nature,and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustrative cross-sectional view of an exemplaryvaporization device.

FIG. 2 is an illustrative cross-sectional view of an exemplaryvaporization device with various electronic features and valves.

FIG. 3 is an illustrative sectional view of another exemplaryvaporization device comprising a condensation chamber, air inlet andaeration vent in the mouthpiece.

FIGS. 4A-4C is an illustrative example of an oven section of anotherexemplary vaporization device configuration with a access lid,comprising an oven having an air inlet, air outlet, and an additionalaeration vent in the airflow pathway, after the oven.

FIG. 5 is an illustrative isometric view of an assembled inhalableaerosol device.

FIGS. 6A-6D are illustrative arrangements and section views of thedevice body and sub-components.

FIG. 7A is an illustrative isometric view of an assembled cartridge.

FIG. 7B is an illustrative exploded isometric view of a cartridgeassembly

FIG. 7C is a side section view of FIG. 7A illustrating the inletchannel, inlet hole and relative placement of the wick, resistiveheating element, and heater contacts, and the heater chamber inside ofthe heater.

FIG. 8A is an illustrative end section view of an exemplary cartridgeinside the heater.

FIG. 8B is an illustrative side view of the cartridge with the capremoved and heater shown in shadow/outline.

FIGS. 9A-9L illustrate an exemplary sequence of one assembly method fora cartridge.

FIGS. 10A-10C are illustrative sequences showing the airflow/vapor pathfor the cartridge.

FIGS. 11, 12, and 13 represent an illustrative assembly sequence forassembling the main components of the device.

FIG. 14 illustrates front, side and section views of the assembledinhalable aerosol device.

FIG. 15 is an illustrative view of an activated, assembled inhalableaerosol device.

FIGS. 16A-16C are representative illustrations of a charging device forthe aerosol device and the application of the charger with the device.

FIGS. 17A and 17B are representative illustrations of aproportional-integral-derivative controller (PID) block diagram andcircuit diagram representing the essential components in a device tocontrol coil temperature.

FIG. 17C is another example of a PID block diagram similar to that ofFIG. 17A, in which the resistance of the resistive heater may be used tocontrol the temperature of the apparatuses described herein.

FIG. 17D is an example of a circuit showing one variation of themeasurement circuit used in the PID block diagram shown in FIG. 17C.Specifically, this is an amplified Wheatstone bridge resistancemeasurement circuit.

FIG. 18 is a device with charging contacts visible from an exteriorhousing of the device.

FIG. 19 is an exploded view of a charging assembly of a device.

FIG. 20 is a detailed view of a charging assembly of a device.

FIG. 21 is a detailed view of charging pins in a charging assembly of adevice.

FIG. 22 is a device in a charging cradle.

FIG. 23 is a circuit provided on a PCB configured to permit a device tocomprise reversible charging contacts.

FIGS. 24A and 24B show top and bottom perspective views, respectively ofa cartridge device holding a vaporizable material for securely couplingwith an electronic inhalable aerosol device as described herein.

FIGS. 25A and 25B show front a side views, respectively, of thecartridge of FIGS. 24A-24B.

FIG. 26A shows a section through a cartridge device holding avaporizable material for securely coupling with an electronic inhalableaerosol device and indicates exemplary dimensions (in mm).

FIG. 26B shows a side view of the cartridge of FIG. 26A, indicatingwhere the sectional view of FIG. 26A was taken.

FIGS. 27A and 27B show an exemplary vaporizer device without a cartridgeattached. FIG. 27A is a side view and FIG. 27B shows a sectional viewwith exemplary dimensions of the rectangular opening for holding andmaking electrical contact with a cartridge.

FIG. 28A shows a perspective view of a vaporizer coupled to a cartridgeas described herein.

FIG. 28B shows a side view of the vaporizer of FIG. 28A.

FIG. 28C shows a sectional view through the vaporizer of FIG. 28B takenthrough the dashed line.

FIG. 28D is an enlarged view of the region showing the electrical andmechanical connection between the cartridge and the vaporizer indictedby the circular region D.

FIGS. 29A-29D illustrate side profiles of alternative variations ofcartridges as described herein.

DETAILED DESCRIPTION

Provided herein are systems and methods for generating a vapor from amaterial. The vapor may be delivered for inhalation by a user. Thematerial may be a solid, liquid, powder, solution, paste, gel, or any amaterial with any other physical consistency. The vapor may be deliveredto the user for inhalation by a vaporization device. The vaporizationdevice may be a handheld vaporization device. The vaporization devicemay be held in one hand by the user.

The vaporization device may comprise a cartridge having one or moreheating elements the heating element may be a resistive heating element.The heating element may heat the material such that the temperature ofthe material increases. Vapor may be generated as a result of heatingthe material. Energy may be required to operate the heating element, theenergy may be derived from a battery in electrical communication withthe heating element. Alternatively a chemical reaction (e.g., combustionor other exothermic reaction) may provide energy to the heating element.

One or more aspects of the vaporization device may be designed and/orcontrolled in order to deliver a vapor with one or more specifiedproperties to the user. For example, aspects of the vaporization devicethat may be designed and/or controlled to deliver the vapor withspecified properties may comprise the heating temperature, heatingmechanism, device air inlets, internal volume of the device, and/orcomposition of the material.

In some cases, a vaporization device may have an “atomizer” or“cartomizer” configured to heat an aerosol forming solution (e.g.,vaporizable material). The aerosol forming solution may compriseglycerin and/or propylene glycol. The vaporizable material may be heatedto a sufficient temperature such that it may vaporize.

An atomizer may be a device or system configured to generate an aerosol.The atomizer may comprise a small heating element configured to heatand/or vaporize at least a portion of the vaporizable material and awicking material that may draw a liquid vaporizable material in to theatomizer. The wicking material may comprise silica fibers, cotton,ceramic, hemp, stainless steel mesh, and/or rope cables. The wickingmaterial may be configured to draw the liquid vaporizable material in tothe atomizer without a pump or other mechanical moving part. Aresistance wire may be wrapped around the wicking material and thenconnected to a positive and negative pole of a current source (e.g.,energy source). The resistance wire may be a coil. When the resistancewire is activated the resistance wire (or coil) may have a temperatureincrease as a result of the current flowing through the resistive wireto generate heat. The heat may be transferred to at least a portion ofthe vaporizable material through conductive, convective, and/orradiative heat transfer such that at least a portion of the vaporizablematerial vaporizes.

Alternatively or in addition to the atomizer, the vaporization devicemay comprise a “cartomizer” to generate an aerosol from the vaporizablematerial for inhalation by the user. The cartomizer may comprise acartridge and an atomizer. The cartomizer may comprise a heating elementsurrounded by a liquid-soaked poly-foam that acts as holder for thevaporizable material (e.g., the liquid). The cartomizer may be reusable,rebuildable, refillable, and/or disposable. The cartomizer may be usedwith a tank for extra storage of a vaporizable material.

Air may be drawn into the vaporization device to carry the vaporizedaerosol away from the heating element, where it then cools and condensesto form liquid particles suspended in air, which may then be drawn outof the mouthpiece by the user.

The vaporization of at least a portion of the vaporizable material mayoccur at lower temperatures in the vaporization device compared totemperatures required to generate an inhalable vapor in a cigarette. Acigarette may be a device in which a smokable material is burned togenerate an inhalable vapor. The lower temperature of the vaporizationdevice may result in less decomposition and/or reaction of the vaporizedmaterial, and therefore produce an aerosol with many fewer chemicalcomponents compared to a cigarette. In some cases, the vaporizationdevice may generate an aerosol with fewer chemical components that maybe harmful to human health compared to a cigarette. Additionally, thevaporization device aerosol particles may undergo nearly completeevaporation in the heating process, the nearly complete evaporation mayyield an average particle size (e.g., diameter) value that may besmaller than the average particle size in tobacco or botanical basedeffluent.

A vaporization device may be a device configured to extract forinhalation one or more active ingredients of plant material, tobacco,and/or a botanical, or other herbs or blends. A vaporization device maybe used with pure chemicals and/or humectants that may or may not bemixed with plant material. Vaporization may be alternative to burning(smoking) that may avoid the inhalation of many irritating and/or toxiccarcinogenic by-products which may result from the pyrolytic process ofburning tobacco or botanical products above 300° C. The vaporizationdevice may operate at a temperature at or below 300° C.

A vaporizer (e.g., vaporization device) may not have an atomizer orcartomizer. Instead the device may comprise an oven. The oven may be atleast partially closed. The oven may have a closable opening. The ovenmay be wrapped with a heating element, alternatively the heating elementmay be in thermal communication with the oven through another mechanism.A vaporizable material may be placed directly in the oven or in acartridge fitted in the oven. The heating element in thermalcommunication with the oven may heat a vaporizable material mass inorder to create a gas phase vapor. The heating element may heat thevaporizable material through conductive, convective, and/or radiativeheat transfer. The vapor may be released to a vaporization chamber wherethe gas phase vapor may condense, forming an aerosol cloud havingtypical liquid vapor particles with particles having a diameter ofaverage mass of approximately 1 micron or greater. In some cases thediameter of average mass may be approximately 0.1-1 micron.

A used herein, the term “vapor” may generally refer to a substance inthe gas phase at a temperature lower than its critical point. The vapormay be condensed to a liquid or to a solid by increasing its pressurewithout reducing the temperature.

As used herein, the term “aerosol” may generally refer to a colloid offine solid particles or liquid droplets in air or another gas. Examplesof aerosols may include clouds, haze, and smoke, including the smokefrom tobacco or botanical products. The liquid or solid particles in anaerosol may have varying diameters of average mass that may range frommonodisperse aerosols, producible in the laboratory, and containingparticles of uniform size; to polydisperse colloidal systems, exhibitinga range of particle sizes. As the sizes of these particles becomelarger, they have a greater settling speed which causes them to settleout of the aerosol faster, making the appearance of the aerosol lessdense and to shorten the time in which the aerosol will linger in air.Interestingly, an aerosol with smaller particles will appear thicker ordenser because it has more particles. Particle number has a much biggerimpact on light scattering than particle size (at least for theconsidered ranges of particle size), thus allowing for a vapor cloudwith many more smaller particles to appear denser than a cloud havingfewer, but larger particle sizes.

As used herein the term “humectant” may generally refer to as asubstance that is used to keep things moist. A humectant may attract andretain moisture in the air by absorption, allowing the water to be usedby other substances. Humectants are also commonly used in many tobaccosor botanicals and electronic vaporization products to keep productsmoist and as vapor-forming medium. Examples include propylene glycol,sugar polyols such as glycerol, glycerin, and honey.

Rapid Aeration

In some cases, the vaporization device may be configured to deliver anaerosol with a high particle density. The particle density of theaerosol may refer to the number of the aerosol droplets relative to thevolume of air (or other dry gas) between the aerosol droplets. A denseaerosol may easily be visible to a user. In some cases the user mayinhale the aerosol and at least a fraction of the aerosol particles mayimpinge on the lungs and/or mouth of the user. The user may exhaleresidual aerosol after inhaling the aerosol. When the aerosol is densethe residual aerosol may have sufficient particle density such that theexhaled aerosol is visible to the user. In some cases, a user may preferthe visual effect and/or mouth feel of a dense aerosol.

A vaporization device may comprise a vaporizable material. Thevaporizable material may be contained in a cartridge or the vaporizablematerial may be loosely placed in one or more cavities the vaporizationdevice. A heating element may be provided in the device to elevate thetemperature of the vaporizable material such that at least a portion ofthe vaporizable material forms a vapor. The heating element may heat thevaporizable material by convective heat transfer, conductive heattransfer, and/or radiative heat transfer. The heating element may heatthe cartridge and/or the cavity in which the vaporizable material isstored.

Vapor formed upon heating the vaporizable material may be delivered tothe user. The vapor may be transported through the device from a firstposition in the device to a second position in the device. In somecases, the first position may be a location where at least a portion ofthe vapor was generated, for example, the cartridge or cavity or an areaadjacent to the cartridge or cavity. The second position may be amouthpiece. The user may suck on the mouthpiece to inhale the vapor.

At least a fraction of the vapor may condense after the vapor isgenerated and before the vapor is inhaled by the user. The vapor maycondense in a condensation chamber. The condensation chamber may be aportion of the device that the vapor passes through before delivery tothe user. In some cases, the device may include at least one aerationvent, placed in the condensation chamber of the vaporization device. Theaeration vent may be configured to introduce ambient air (or other gas)into the vaporization chamber. The air introduced into the vaporizationchamber may have a temperature lower than the temperature of a gasand/or gas/vapor mixture in the condensation chamber. Introduction ofthe relatively lower temperature gas into the vaporization chamber mayprovide rapid cooling of the heated gas vapor mixture that was generatedby heating the vaporizable material. Rapid cooling of the gas vapormixture may generate a dense aerosol comprising a high concentration ofliquid droplets having a smaller diameter and/or smaller average masscompared to an aerosol that is not rapidly cooled prior to inhalation bythe user.

An aerosol with a high concentration of liquid droplets having a smallerdiameter and/or smaller average mass compared to an aerosol that is notrapidly cooled prior to inhalation by the user may be formed in atwo-step process. The first step may occur in the oven chamber where thevaporizable material (e.g., tobacco and/or botanical and humectantblend) may be heated to an elevated temperature. At the elevatedtemperature, evaporation may happen faster than at room temperature andthe oven chamber may fill with the vapor phase of the humectants. Thehumectant may continue to evaporate until the partial pressure of thehumectant is equal to the saturation pressure. At this point, the gas issaid to have a saturation ratio of 1 (S=P_(partial)1/P_(sat)).

In the second step, the gas (e.g., vapor and air) may exit the oven andenter a condenser or condensation chamber and begin to cool. As the gasphase vapor cools, the saturation pressure may decrease. As thesaturation pressure decreases, the saturation ratio may increase and thevapor may begin to condense, forming droplets. In some devices, with theabsence of added cooling aeration, the cooling may be relatively slowersuch that high saturation pressures may not be reached, and the dropletsthat form in the devices without added cooling aeration may berelatively larger and fewer in numbers. When cooler air is introduced, atemperature gradient may be formed between the cooler air and therelatively warmer gas in the device. Mixing between the cooler air andthe relatively warmer gas in a confined space inside of the vaporizationdevice may lead to rapid cooling. The rapid cooling may generate highsaturation ratios, small particles, and high concentrations of smallerparticles, forming a thicker, denser vapor cloud compared to particlesgenerated in a device without the aeration vents.

For the purpose of this disclosure, when referring to ratios ofhumectants such as vegetable glycerol or propylene glycol, “about” meansa variation of 5%, 10%, 20% or 25% depending on the embodiment.

For the purpose of this disclosure, when referring to a diameter ofaverage mass in particle sizes, “about” means a variation of 5%, 10%,20% or 25% depending on the embodiment.

A vaporization device configured to rapidly cool a vapor may comprise: amouthpiece comprising an aerosol outlet at a first end of the device; anoven comprising an oven chamber and a heater for heating a vapor formingmedium in the oven chamber and for forming a vapor therein; a condensercomprising a condensation chamber in which the vapor forms the inhalableaerosol; an air inlet that originates a first airflow path that includesthe oven chamber and then the condensation chamber, an aeration ventthat originates a second airflow path that joins the first airflow pathprior to or within the condensation chamber after the vapor is formed inthe oven chamber, wherein the joined first airflow path and secondairflow path are configured to deliver the inhalable aerosol formed inthe condensation chamber through the aerosol outlet of the mouthpiece toa user.

In some embodiments, the oven is within a body of the device. The ovenchamber may comprise an oven chamber inlet and an oven chamber outlet.The oven may further comprise a first valve at the oven chamber inlet,and a second valve at the oven chamber outlet.

The oven may be contained within a device housing. In some cases thebody of the device may comprise the aeration vent and/or the condenser.The body of the device may comprise one or more air inlets. The body ofthe device may comprise a housing that holds and/or at least partiallycontains one or more elements of the device.

The mouthpiece may be connected to the body. The mouthpiece may beconnected to the oven. The mouthpiece may be connected to a housing thatat least partially encloses the oven. In some cases, the mouthpiece maybe separable from the oven, the body, and/or the housing that at leastpartially encloses the oven. The mouthpiece may comprise at least one ofthe air inlet, the aeration vent, and the condenser. The mouthpiece maybe integral to the body of the device. The body of the device maycomprise the oven.

In some cases, the one or more aeration vents may comprise a valve. Thevalve may regulate a flow rate of air entering the device through theaeration vent. The valve may be controlled through a mechanical and/orelectrical control system.

A vaporization device configured to rapidly cool a vapor may comprise: abody, a mouthpiece, an aerosol outlet, a condenser with a condensationchamber, a heater, an oven with an oven chamber, a primary airflowinlet, and at least one aeration vent provided in the body, downstreamof the oven, and upstream of the mouthpiece.

FIG. 1 shows an example of a vaporization device configured to rapidlycool a vapor. The device 100, may comprise a body 101. The body mayhouse and/or integrate with one or more components of the device. Thebody may house and/or integrate with a mouthpiece 102. The mouthpiece102 may have an aerosol outlet 122. A user may inhale the generatedaerosol through the aerosol outlet 122 on the mouthpiece 102. The bodymay house and/or integrate with an oven region 104. The oven region 104may comprise an oven chamber where vapor forming medium 106 may beplaced. The vapor forming medium may include tobacco and/or botanicals,with or without a secondary humectant. In some cases the vapor formingmedium may be contained in a removable and/or refillable cartridge.

Air may be drawn into the device through a primary air inlet 121. Theprimary air inlet 121 may be on an end of the device 100 opposite themouthpiece 102. Alternatively, the primary air inlet 121 may be adjacentto the mouthpiece 102. In some cases, a pressure drop sufficient to pullair into the device through the primary air inlet 121 may be due to auser puffing on the mouthpiece 102.

The vapor forming medium (e.g., vaporizable material) may be heated inthe oven chamber by a heater 105, to generate elevated temperature gasphases (vapor) of the tobacco or botanical and humectant/vapor formingcomponents. The heater 105 may transfer heat to the vapor forming mediumthrough conductive, convective, and/or radiative heat transfer. Thegenerated vapor may be drawn out of the oven region and into thecondensation chamber 103 a, of the condenser 103 where the vapors maybegin to cool and condense into micro-particles or droplets suspended inair, thus creating the initial formation of an aerosol, before beingdrawn out of the mouthpiece through the aerosol outlet 122.

In some cases, relatively cooler air may be introduced into thecondensation chamber 103 a, through an aeration vent 107 such that thevapor condenses more rapidly compared to a vapor in a device without theaeration vent 107. Rapidly cooling the vapor may create a denser aerosolcloud having particles with a diameter of average mass of less than orequal to about 1 micron, and depending on the mixture ratio of thevapor-forming humectant, particles with a diameter of average mass ofless than or equal to about 0.5 micron

Also described herein are devices for generating an inhalable aerosolsaid device comprising a body with a mouthpiece at one end, an attachedbody at the other end comprising a condensation chamber, a heater, anoven, wherein the oven comprises a first valve in the airflow path atthe primary airflow inlet of the oven chamber, and a second valve at theoutlet end of the oven chamber, and at least one aeration vent providedin the body, downstream of the oven, and upstream of the mouthpiece.

FIG. 2 shows a diagram of an alternative embodiment of the vaporizationdevice 200. The vaporization device may have a body 201. The body 201may integrate with and/or contain one or more components of the device.The body may integrate with or be connected to a mouthpiece 202

The body may comprise an oven region 204, with an oven chamber 204 ahaving a first constricting valve 208 in the primary air inlet of theoven chamber and a second constricting valve 209 at the oven chamberoutlet. The oven chamber 204 a may be sealed with a tobacco or botanicaland/or humectant/vapor forming medium 206 therein. The seal may be anair tight and/or liquid tight seal. The heater may be provided to theoven chamber with a heater 205. The heater 205 may be in thermalcommunication with the oven, for example the heater may be surroundingthe oven chamber during the vaporization process. Heater may contact theoven. The heater may be wrapped around the oven. Before inhalation andbefore air is drawn in through a primary air inlet 221, pressure maybuild in the sealed oven chamber as heat is continually added. Thepressure may build due to a phase change of the vaporizable material.Elevated temperature gas phases (vapor) of the tobacco or botanical andhumectant/vapor forming components may be achieved by continually addingheat to the oven. This heated pressurization process may generate evenhigher saturation ratios when the valves 208, 209 are opened duringinhalation. The higher saturation ratios may cause relatively higherparticle concentrations of gas phase humectant in the resultant aerosol.When the vapor is drawn out of the oven region and into the condensationchamber 203 a of the condenser 203, for example by inhalation by theuser, the gas phase humectant vapors may be exposed to additional airthrough an aeration vent 207, and the vapors may begin to cool andcondense into droplets suspended in air. As described previously theaerosol may be drawn through the mouthpiece 222 by the user. Thiscondensation process may be further refined by adding an additionalvalve 210, to the aeration vent 207 to further control the air-vapormixture process.

FIG. 2 also illustrates an exemplary embodiment of the additionalcomponents which would be found in a vaporizing device, including apower source or battery 211, a printed circuit board 212, a temperatureregulator 213, and operational switches (not shown), housed within aninternal electronics housing 214, to isolate them from the damagingeffects of the moisture in the vapor and/or aerosol. The additionalcomponents may be found in a vaporizing device that may or may notcomprise an aeration vent as described above.

In some embodiments of the vaporization device, components of the deviceare user serviceable, such as the power source or battery. Thesecomponents may be replaceable or rechargeable.

Also described herein are devices for generating an inhalable aerosolsaid device comprising a first body, a mouthpiece having an aerosoloutlet, a condensation chamber within a condenser and an airflow inletand channel, an attached second body, comprising a heater and oven withan oven chamber, wherein said airflow channel is upstream of the ovenand the mouthpiece outlet to provide airflow through the device, acrossthe oven, and into the condensation chamber where an auxiliary aerationvent is provided.

FIG. 3 shows a section view of a vaporization device 300. The device 300may comprise a body 301. The body may be connected to or integral with amouthpiece 302 at one end. The mouthpiece may comprise a condensationchamber 303 a within a condenser section 303 and an airflow inlet 321and air channel 323. The device body may comprise a proximally locatedoven 304 comprising an oven chamber 304 a. The oven chamber may be inthe body of the device. A vapor forming medium 306 (e.g., vaporizablematerial) comprising tobacco or botanical and humectant vapor formingmedium may be placed in the oven. The vapor forming medium may be indirect contact with an air channel 323 from the mouthpiece. The tobaccoor botanical may be heated by heater 305 surrounding the oven chamber,to generate elevated temperature gas phases (vapor) of the tobacco orbotanical and humectant/vapor forming components and air drawn inthrough a primary air inlet 321, across the oven, and into thecondensation chamber 303 a of the condenser region 303 due to a userpuffing on the mouthpiece. Once in the condensation chamber where thegas phase humectant vapors begin to cool and condense into dropletssuspended in air, additional air is allowed to enter through aerationvent 307, thus, once again creating a denser aerosol cloud havingparticles with a diameter of average mass of less than a typicalvaporization device without an added aeration vent, before being drawnout of the mouthpiece through the aerosol outlet 322.

The device may comprises a mouthpiece comprising an aerosol outlet at afirst end of the device and an air inlet that originates a first airflowpath; an oven comprising an oven chamber that is in the first airflowpath and includes the oven chamber and a heater for heating a vaporforming medium in the oven chamber and for forming a vapor therein, acondenser comprising a condensation chamber in which the vapor forms theinhalable aerosol, an aeration vent that originates a second airflowpath that allows air from the aeration vent to join the first airflowpath prior to or within the condensation chamber and downstream from theoven chamber thereby forming a joined path, wherein the joined path isconfigured to deliver the inhalable aerosol formed in the condensationchamber through the aerosol outlet of the mouthpiece to a user.

The device may comprise a mouthpiece comprising an aerosol outlet at afirst end of the device, an air inlet that originates a first airflowpath, and an aeration vent that originates a second airflow path thatallows air from the aeration vent to join the first airflow path; anoven comprising an oven chamber that is in the first airflow path andincludes the oven chamber and a heater for heating a vapor formingmedium in the oven chamber and for forming a vapor therein, a condensercomprising a condensation chamber in which the vapor forms the inhalableaerosol and wherein air from the aeration vent joins the first airflowpath prior to or within the condensation chamber and downstream from theoven chamber thereby forming a joined path, wherein the joined path isconfigured to deliver the inhalable aerosol through the aerosol outletof the mouthpiece to a user, as illustrated in exemplary FIG. 3.

The device may comprise a body with one or more separable components.For example, the mouthpiece may be separably attached to the bodycomprising the condensation chamber, a heater, and an oven, asillustrated in exemplary FIG. 1 or 2.

The device may comprise a body with one or more separable components.For example, the mouthpiece may be separably attached to the body. Themouthpiece may comprise the condensation chamber, and may be attached toor immediately adjacent to the oven and which is separable from the bodycomprising a heater, and the oven, as illustrated in exemplary FIG. 3.

The at least one aeration vent may be located in the condensationchamber of the condenser, as illustrated in exemplary FIG. 1, 2, or 3.The at least one aeration vent may comprise a third valve in the airflowpath of the at least one aeration vent, as illustrated in exemplary FIG.2. The first, second and third valve is a check valve, a clack valve, anon-return valve, or a one-way valve. In any of the precedingvariations, the first, second or third valve may be mechanicallyactuated, electronically actuated or manually actuated. One skilled inthe art will recognize after reading this disclosure that this devicemay be modified in a way such that any one, or each of these openings orvents could be configured to have a different combination or variationof mechanisms as described to control airflow, pressure and temperatureof the vapor created and aerosol being generated by these deviceconfigurations, including a manually operated opening or vent with orwithout a valve.

The device may further comprise at least one of: a power source, aprinted circuit board, a switch, and a temperature regulator.Alternately, one skilled in the art would recognize that eachconfiguration previously described will also accommodate said powersource (battery), switch, printed circuit board, or temperatureregulator as appropriate, in the body.

The device may be disposable when the supply of pre-packagedaerosol-forming media is exhausted. Alternatively, the device may berechargeable such that the battery may be rechargeable or replaceable,and /or the aerosol-forming media may be refilled, by the user/operatorof the device. Still further, the device may be rechargeable such thatthe battery may be rechargeable or replaceable, and/or the operator mayalso add or refill a tobacco or botanical component, in addition to arefillable or replaceable aerosol-forming media to the device.

As illustrated in FIG. 1, 2 or 3, the vaporization device may comprisetobacco or a botanical heated in said oven chamber, wherein said tobaccoor botanical further comprises humectants to produce an aerosolcomprising gas phase components of the humectant and tobacco orbotanical. The gas phase humectant and tobacco or botanical vaporproduced by said heated aerosol forming media 106, 206, 306 may furtherbe mixed with air from a special aeration vent 107, 207, 307 afterexiting the oven area 104, 204, 304 and entering a condensation chamber103 a, 203 a, 303 a to cool and condense said gas phase vapors toproduce a far denser, thicker aerosol comprising more particles thanwould have otherwise been produced without the extra cooling air, with adiameter of average mass of less than or equal to about 1 micron.

Each aerosol configuration produced by mixing the gas phase vapors withthe cool air may comprise a different range of particles, for example;with a diameter of average mass of less than or equal to about 0.9micron; less than or equal to about 0.8 micron; less than or equal toabout 0.7 micron; less than or equal to about 0.6 micron; and even anaerosol comprising particle diameters of average mass of less than orequal to about 0.5 micron.

The possible variations and ranges of aerosol density are great in thatthe possible number of combinations of temperature, pressure, tobacco orbotanical choices and humectant selections are numerous. However, byexcluding the tobacco or botanical choices and limiting the temperaturesranges and the humectant ratios to those described herein, the inventorhas demonstrated that this device will produce a far denser, thickeraerosol comprising more particles than would have otherwise beenproduced without the extra cooling air, with a diameter of average massof less than or equal to about 1 micron.

The humectant may comprise glycerol or vegetable glycerol as avapor-forming medium.

The humectant may comprise propylene glycol as a vapor-forming medium.

In preferred embodiments, the humectant may comprise a ratio ofvegetable glycerol to propylene glycol as a vapor-forming medium. Theranges of said ratio may vary between a ratio of about 100:0 vegetableglycerol to propylene glycol and a ratio of about 50:50 vegetableglycerol to propylene glycol. The difference in preferred ratios withinthe above stated range may vary by as little as 1, for example, saidratio may be about 99:1 vegetable glycerol to propylene glycol. However,more commonly said ratios would vary in increments of about 5, forexample, about 95:5 vegetable glycerol to propylene glycol; or about85:15 vegetable glycerol to propylene glycol; or about 55:45 vegetableglycerol to propylene glycol.

In a preferred embodiment the ratio for the vapor forming medium will bebetween the ratios of about 80:20 vegetable glycerol to propyleneglycol, and about 60:40 vegetable glycerol to propylene glycol.

In a most preferred embodiment, the ratio for the vapor forming mediumwill be about 70:30 vegetable glycerol to propylene glycol.

In any of the preferred embodiments, the humectant may further compriseflavoring products. These flavorings may include enhancers comprisingcocoa solids, licorice, tobacco or botanical extracts, and varioussugars, to name but a few.

The tobacco or botanical may be heated in the oven up to its pyrolytictemperature, which as noted previously is most commonly measured in therange of 300-1000° C.

In preferred embodiments, the tobacco or botanical is heated to about300° C. at most. In other preferred embodiments, the tobacco orbotanical is heated to about 200° C. at most. In still other preferredembodiments, the tobacco or botanical is heated to about 160° C. atmost. It should be noted that in these lower temperature ranges (<300°C.), pyrolysis of tobacco or botanical does not typically occur, yetvapor formation of the tobacco or botanical components and flavoringproducts does occur. In addition, vapor formation of the components ofthe humectant, mixed at various ratios will also occur, resulting innearly complete vaporization, depending on the temperature, sincepropylene glycol has a boiling point of about 180°-190° C. and vegetableglycerin will boil at approximately 280°-290° C.

In still other preferred embodiments, the aerosol produced by saidheated tobacco or botanical and humectant is mixed with air providedthrough an aeration vent.

In still other preferred embodiments, the aerosol produced by saidheated tobacco or botanical and humectant mixed with air, is cooled to atemperature of about 50°-70° C. at most, and even as low as 35° C.before exiting the mouthpiece, depending on the air temperature beingmixed into the condensation chamber. In some embodiments, thetemperature is cooled to about 35°-55° C. at most, and may have afluctuating range of ± about 10° C. or more within the overall range ofabout 35°-70° C.

Also described herein are vaporization devices for generating aninhalable aerosol comprising a unique oven configuration, wherein saidoven comprises an access lid and an auxiliary aeration vent locatedwithin the airflow channel immediately downstream of the oven and beforethe aeration chamber. In this configuration, the user may directlyaccess the oven by removing the access lid, providing the user with theability to recharge the device with vaporization material.

In addition, having the added aeration vent in the airflow channelimmediately after the oven and ahead of the vaporization chamberprovides the user with added control over the amount of air entering theaeration chamber downstream and the cooling rate of the aerosol beforeit enters the aeration chamber.

As noted in FIGS. 4A-4C, the device 400 may comprise a body 401, havingan air inlet 421 allowing initial air for the heating process into theoven region 404. After heating the tobacco or botanical, and humectant(heater not shown), the gas phase humectant vapor generated may traveldown the airflow channel 423, passing the added aeration vent 407wherein the user may selectively increase airflow into the heated vapor.The user may selectively increase and/or decrease the airflow to theheated vapor by controlling a valve in communication with the aerationvent 407. In some cases, the device may not have an aeration vent.Airflow into the heated vapor through the aeration vent may decrease thevapor temperature before exiting the airflow channel at the outlet 422,and increase the condensation rate and vapor density by decreasing thediameter of the vapor particles within the aeration chamber (not shown),thus producing a thicker, denser vapor compared to the vapor generatedby a device without the aeration vent. The user may also access the ovenchamber 404 a to recharge or reload the device 400, through an accesslid 430 provided therein, making the device user serviceable. The accesslid may be provided on a device with or without an aeration vent.

Provided herein is a method for generating an inhalable aerosol, themethod comprising: providing an vaporization device, wherein said deviceproduces a vapor comprising particle diameters of average mass of about1 micron or less, wherein the vapor is formed by heating a vapor formingmedium in an oven chamber of the device to a first temperature below thepyrolytic temperature of the vapor forming medium, and cooling the vaporin a condensation chamber to a temperature below the first temperature,before exiting an aerosol outlet of said device.

In some embodiments the vapor may be cooled by mixing relatively coolerair with the vapor in the condensation chamber during the condensationphase, after leaving the oven, where condensation of the gas phasehumectants occurs more rapidly due to high saturation ratios beingachieved at the moment of aeration, producing a higher concentration ofsmaller particles, with fewer by-products, in a denser aerosol, thanwould normally occur in a standard vaporization or aerosol generatingdevice.

In some embodiments, formation of an inhalable aerosol is a two-stepprocess. The first step occurs in the oven where the tobacco orbotanical and humectant blend is heated to an elevated temperature. Atthe elevated temperature, evaporation happens faster than at roomtemperature and the oven chamber fills with the vapor phase of thehumectants. The humectant will continue to evaporate until the partialpressure of the humectant is equal to the saturation pressure. At thispoint, the gas is said to have a saturation ratio of 1(S=P_(partial)/P_(sat)).

In the second step, the gas leaves the oven chamber, passes to acondensation chamber in a condenser and begins to cool. As the gas phasevapor cools, the saturation pressure also goes down, causing thesaturation ratio to rise, and the vapor to condensate, forming droplets.When cooling air is introduced, the large temperature gradient betweenthe two fluids mixing in a confined space leads to very rapid cooling,causing high saturation ratios, small particles, and higherconcentrations of smaller particles, forming a thicker, denser vaporcloud.

Provided herein is a method for generating an inhalable aerosolcomprising: a vaporization device having a body with a mouthpiece at oneend, and an attached body at the other end comprising; a condenser witha condensation chamber, a heater, an oven with an oven chamber, and atleast one aeration vent provided in the body, downstream of the oven,and upstream of the mouthpiece, wherein tobacco or botanical comprisinga humectant is heated in said oven chamber to produce a vapor comprisinggas phase humectants.

As previously described, a vaporization device having an auxiliaryaeration vent located in the condensation chamber capable of supplyingcool air (relative to the heated gas components) to the gas phase vaporsand tobacco or botanical components exiting the oven region, may beutilized to provide a method for generating a far denser, thickeraerosol comprising more particles than would have otherwise beenproduced without the extra cooling air, with a diameter of average massof less than or equal to about 1 micron.

In another aspect, provided herein is a method for generating aninhalable aerosol comprising: a vaporization device, having a body witha mouthpiece at one end, and an attached body at the other endcomprising: a condenser with a condensation chamber, a heater, an ovenwith an oven chamber, wherein said oven chamber further comprises afirst valve in the airflow path at the inlet end of the oven chamber,and a second valve at the outlet end of the oven chamber; and at leastone aeration vent provided in said body, downstream of the oven, andupstream of the mouthpiece wherein tobacco or botanical comprising ahumectant is heated in said oven chamber to produce a vapor comprisinggas phase humectants.

As illustrated in exemplary FIG. 2, by sealing the oven chamber 204 awith a tobacco or botanical and humectant vapor forming medium 206therein, and applying heat with the heater 205 during the vaporizationprocess, before inhalation and air is drawn in through a primary airinlet 221, the pressure will build in the oven chamber as heat iscontinually added with an electronic heating circuit generated throughthe combination of the battery 211, printed circuit board 212,temperature regulator 213, and operator controlled switches (not shown),to generate even greater elevated temperature gas phase humectants(vapor) of the tobacco or botanical and humectant vapor formingcomponents. This heated pressurization process generates even highersaturation ratios when the valves 208, 209 are opened during inhalation,which cause higher particle concentrations in the resultant aerosol,when the vapor is drawn out of the oven region and into the condensationchamber 203 a, where they are again exposed to additional air through anaeration vent 207, and the vapors begin to cool and condense intodroplets suspended in air, as described previously before the aerosol iswithdrawn through the mouthpiece 222. The inventor also notes that thiscondensation process may be further refined by adding an additionalvalve 210, to the aeration vent 207 to further control the air-vapormixture process.

In some embodiments of any one of the inventive methods, the first,second and/or third valve is a one-way valve, a check valve, a clackvalve, or a non-return valve. The first, second and/or third valve maybe mechanically actuated. The first, second and/or third valve may beelectronically actuated. The first, second and/or third valve may beautomatically actuated. The first, second and/or third valve may bemanually actuated either directly by a user or indirectly in response toan input command from a user to a control system that actuates thefirst, second and/or third valve.

In other aspects of the inventive methods, said device further comprisesat least one of: a power source, a printed circuit board, or atemperature regulator.

In any of the preceding aspects of the inventive method, one skilled inthe art will recognize after reading this disclosure that this methodmay be modified in a way such that any one, or each of these openings orvents could be configured to have a different combination or variationof mechanisms or electronics as described to control airflow, pressureand temperature of the vapor created and aerosol being generated bythese device configurations, including a manually operated opening orvent with or without a valve.

The possible variations and ranges of aerosol density are great in thatthe possible number of temperature, pressure, tobacco or botanicalchoices and humectant selections and combinations are numerous. However,by excluding the tobacco or botanical choices and limiting thetemperatures to within the ranges and the humectant ratios describedherein, the inventor has demonstrated a method for generating a fardenser, thicker aerosol comprising more particles than would haveotherwise been produced without the extra cooling air, with a diameterof average mass of less than or equal to 1 micron.

In some embodiments of the inventive methods, the humectant comprises aratio of vegetable glycerol to propylene glycol as a vapor-formingmedium. The ranges of said ratio will vary between a ratio of about100:0 vegetable glycerol to propylene glycol and a ratio of about 50:50vegetable glycerol to propylene glycol. The difference in preferredratios within the above stated range may vary by as little as 1, forexample, said ratio may be about 99:1 vegetable glycerol to propyleneglycol. However, more commonly said ratios would vary in increments of5, for example, about 95:5 vegetable glycerol to propylene glycol; orabout 85:15 vegetable glycerol to propylene glycol; or about 55:45vegetable glycerol to propylene glycol.

Because vegetable glycerol is less volatile than propylene glycol, itwill recondense in greater proportions. A humectant with higherconcentrations of glycerol will generate a thicker aerosol. The additionof propylene glycol will lead to an aerosol with a reduced concentrationof condensed phase particles and an increased concentration of vaporphase effluent. This vapor phase effluent is often perceived as a tickleor harshness in the throat when the aerosol is inhaled. To someconsumers, varying degrees of this sensation may be desirable. The ratioof vegetable glycerol to propylene glycol may be manipulated to balanceaerosol thickness with the right amount of “throat tickle.”

In a preferred embodiment of the method, the ratio for the vapor formingmedium will be between the ratios of about 80:20 vegetable glycerol topropylene glycol, and about 60:40 vegetable glycerol to propyleneglycol.

In a most preferred embodiment of the method, the ratio for the vaporforming medium will be about 70:30 vegetable glycerol to propyleneglycol. On will envision that there will be blends with varying ratiosfor consumers with varying preferences.

In any of the preferred embodiments of the method, the humectant furthercomprises flavoring products. These flavorings include enhancers such ascocoa solids, licorice, tobacco or botanical extracts, and varioussugars, to name a few.

In some embodiments of the method, the tobacco or botanical is heated toits pyrolytic temperature.

In preferred embodiments of the method, the tobacco or botanical isheated to about 300° C. at most.

In other preferred embodiments of the method, the tobacco or botanicalis heated to about 200° C. at most. In still other embodiments of themethod, the tobacco or botanical is heated to about 160° C. at most.

As noted previously, at these lower temperatures, (<300° C.), pyrolysisof tobacco or botanical does not typically occur, yet vapor formation ofthe tobacco or botanical components and flavoring products does occur.As may be inferred from the data supplied by Baker et al., an aerosolproduced at these temperatures is also substantially free from Hoffmananalytes or at least 70% less Hoffman analytes than a common tobacco orbotanical cigarette and scores significantly better on the Ames testthan a substance generated by burning a common cigarette. In addition,vapor formation of the components of the humectant, mixed at variousratios will also occur, resulting in nearly complete vaporization,depending on the temperature, since propylene glycol has a boiling pointof about 180°-190° C. and vegetable glycerin will boil at approximately280°-290° C.

In any one of the preceding methods, said inhalable aerosol produced bytobacco or a botanical comprising a humectant and heated in said ovenproduces an aerosol comprising gas phase humectants is further mixedwith air provided through an aeration vent.

In any one of the preceding methods, said aerosol produced by saidheated tobacco or botanical and humectant mixed with air, is cooled to atemperature of about 50°-70° C., and even as low as 35° C., beforeexiting the mouthpiece. In some embodiments, the temperature is cooledto about 35°-55° C. at most, and may have a fluctuating range of ± about10° C. or more within the overall range of about 35°-70° C.

In some embodiments of the method, the vapor comprising gas phasehumectant may be mixed with air to produce an aerosol comprisingparticle diameters of average mass of less than or equal to about 1micron.

In other embodiments of the method, each aerosol configuration producedby mixing the gas phase vapors with the cool air may comprise adifferent range of particles, for example; with a diameter of averagemass of less than or equal to about 0.9 micron; less than or equal toabout 0.8 micron; less than or equal to about 0.7 micron; less than orequal to about 0.6 micron; and even an aerosol comprising particlediameters of average mass of less than or equal to about 0.5 micron.

Cartridge Design and Vapor Generation from Material in Cartridge

In some cases, a vaporization device may be configured to generate aninhalable aerosol. A device may be a self-contained vaporization device.The device may comprise an elongated body which functions to complementaspects of a separable and recyclable cartridge with air inlet channels,air passages, multiple condensation chambers, flexible heater contacts,and multiple aerosol outlets. Additionally, the cartridge may beconfigured for ease of manufacture and assembly.

Provided herein is a vaporization device for generating an inhalableaerosol. The device may comprise a device body, a separable cartridgeassembly further comprising a heater, at least one condensation chamber,and a mouthpiece. The device provides for compact assembly anddisassembly of components with detachable couplings; overheat shut-offprotection for the resistive heating element; an air inlet passage (anenclosed channel) formed by the assembly of the device body and aseparable cartridge; at least one condensation chamber within theseparable cartridge assembly; heater contacts; and one or morerefillable, reusable, and/or recyclable components.

Provided herein is a device for generating an inhalable aerosolcomprising: a device body comprising a cartridge receptacle; a cartridgecomprising: a storage compartment, and a channel integral to an exteriorsurface of the cartridge, and an air inlet passage formed by the channeland an internal surface of the cartridge receptacle when the cartridgeis inserted into the cartridge receptacle. The cartridge may be formedfrom a metal, plastic, ceramic, and/or composite material. The storagecompartment may hold a vaporizable material. FIG. 7A shows an example ofa cartridge 30 for use in the device. The vaporizable material may be aliquid at or near room temperature. In some cases the vaporizablematerial may be a liquid below room temperature. The channel may form afirst side of the air inlet passage, and an internal surface of thecartridge receptacle may form a second side of the air inlet passage, asillustrated in various non-limiting aspects of FIGS. 5-6D, 7C,8A, 8B,and 10A

Provided herein is a device for generating an inhalable aerosol. Thedevice may comprise a body that houses, contains, and or integrates withone or more components of the device. The device body may comprise acartridge receptacle. The cartridge receptacle may comprise a channelintegral to an interior surface of the cartridge receptacle; and an airinlet passage formed by the channel and an external surface of thecartridge when the cartridge is inserted into the cartridge receptacle.A cartridge may be fitted and/or inserted into the cartridge receptacle.The cartridge may have a fluid storage compartment. The channel may forma first side of the air inlet passage, and an external surface of thecartridge forms a second side of the air inlet passage. The channel maycomprise at least one of: a groove; a trough; a track; a depression; adent; a furrow; a trench; a crease; and a gutter. The integral channelmay comprise walls that are either recessed into the surface or protrudefrom the surface where it is formed. The internal side walls of thechannel may form additional sides of the air inlet passage. The channelmay have a round, oval, square, rectangular, or other shaped crosssection. The channel may have a closed cross section. The channel may beabout 0.1 cm, 0.5 cm, 1 cm, 2 cm, or 5 cm wide. The channel may be about0.1 mm, 0.5 mm, 1 mm, 2 mm, or 5 mm deep. The channel may be about 0.1cm, 0.5 cm, 1 cm, 2 cm, or 5 cm long. There may be at least 1 channel.

In some embodiments, the cartridge may further comprise a second airpassage in fluid communication with the air inlet passage to the fluidstorage compartment, wherein the second air passage is formed throughthe material of the cartridge.

FIGS. 5-7C show various views of a compact electronic device assembly 10for generating an inhalable aerosol. The compact electronic device 10may comprise a device body 20 with a cartridge receptacle 21 forreceiving a cartridge 30. The device body may have a square orrectangular cross section. Alternatively, the cross section of the bodymay be any other regular or irregular shape. The cartridge receptaclemay be shaped to receive an opened cartridge 30 a or “pod”. Thecartridge may be opened when a protective cap is removed from a surfaceof the cartridge. In some cases, the cartridge may be opened when a holeor opening is formed on a surface of the cartridge. The pod 30 a may beinserted into an open end of the cartridge receptacle 21 so that anexposed first heater contact tips 33 a on the heater contacts 33 of thepod make contact with the second heater contacts 22 of the device body,thus forming the device assembly 10.

Referring to FIG. 14, it is apparent in the plan view that when the pod30 a is inserted into the notched body of the cartridge receptacle 21,the channel air inlet 50 is left exposed. The size of the channel airinlet 50 may be varied by altering the configuration of the notch in thecartridge receptacle 21.

The device body may further comprise a rechargeable battery, a printedcircuit board (PCB) 24 containing a microcontroller with the operatinglogic and software instructions for the device, a pressure switch 27 forsensing the user's puffing action to activate the heater circuit, anindicator light 26, charging contacts (not shown), and an optionalcharging magnet or magnetic contact (not shown). The cartridge mayfurther comprise a heater 36. The heater may be powered by therechargeable battery. The temperature of the heater may be controlled bythe microcontroller. The heater may be attached to a first end of thecartridge.

In some embodiments, the heater may comprise a heater chamber 37, afirst pair of heater contacts 33, 33′, a fluid wick 34, and a resistiveheating element 35 in contact with the wick. The first pair of heatercontacts may comprise thin plates affixed about the sides of the heaterchamber. The fluid wick and resistive heating element may be suspendedbetween the heater contacts.

In some embodiments, there may be two or more resistive heating elements35, 35′ and two or more wicks 34, 34′. In some of the embodiments, theheater contact 33 may comprise: a flat plate; a male contact; a femalereceptacle, or both; a flexible contact and/or copper alloy or anotherelectrically conductive material. The first pair of heater contacts mayfurther comprise a formed shape that may comprise a tab (e.g., flange)having a flexible spring value that extends out of the heater tocomplete a circuit with the device body. The first pair of heatercontact may be a heat sink that absorb and dissipate excessive heatproduced by the resistive heating element. Alternatively, the first pairof heater contacts may be a heat shield that protects the heater chamberfrom excessive heat produced by the resistive heating element. The firstpair of heater contacts may be press-fit to an attachment feature on theexterior wall of the first end of the cartridge. The heater may enclosea first end of the cartridge and a first end of the fluid storagecompartment.

As illustrated in the exploded assembly of FIG. 7B, a heater enclosuremay comprises two or more heater contacts 33, each comprising a flatplate which may be machined or stamped from a copper alloy or similarelectrically conductive material. The flexibility of the tip is providedby the cut-away clearance feature 33 b created below the male contactpoint tip 33 a which capitalizes on the inherent spring capacity of themetal sheet or plate material. Another advantage and improvement of thistype of contact is the reduced space requirement, simplifiedconstruction of a spring contact point (versus a pogo pin) and the easyof assembly. The heater may comprise a first condensation chamber. Theheater may comprise more one or more additional condensation chambers inaddition to the first condensation chamber. The first condensationchamber may be formed along an exterior wall of the cartridge.

In some cases, the cartridge (e.g., pod) is configured for ease ofmanufacturing and assembly. The cartridge may comprise an enclosure. Theenclosure may be a tank. The tank may comprise an interior fluid storagecompartment 32. The interior fluid storage compartment 32 which is openat one or both ends and comprises raised rails on the side edges 45 band 46 b. The cartridge may be formed from plastic, metal, composite,and/or a ceramic material. The cartridge may be rigid or flexible.

The tank may further comprise a set of first heater contact plates 33formed from copper alloy or another electrically conductive material,having a thin cut-out 33 b below the contact tips 33 a (to create aflexible tab) which are affixed to the sides of the first end of thetank and straddle the open-sided end 53 of the tank. The plates mayaffix to pins, or posts as shown in FIG. 7B or 5, or may be attached byother common means such as compression beneath the enclosure 36. A fluidwick 34 having a resistive heating element 35 wrapped around it, isplaced between the first heater contact plates 33, and attached thereto.A heater 36, comprising raised internal edges on the internal end (notshown), a thin mixing zone (not shown), and primary condensation channelcovers 45 a that slide over the rails 45 b on the sides of the tank onthe first half of the tank, creating a primary condensationchannel/chamber 45. In addition, a small male snap feature 39 b locatedat the end of the channel cover is configured fall into a female snapfeature 39 a, located mid-body on the side of the tank, creating asnap-fit assembly.

As will be further clarified below, the combination of the open-sidedend 53, the protruding tips 33 a of the contact plates 33, the fluidwick 34 having a resistive heating element 35, enclosed in the open endof the fluid storage tank, under the heater 36, with a thin mixing zonetherein, creates an efficient heater system. In addition, the primarycondensation channel covers 45 a which slide over the rails 45 b on thesides of the tank create an integrated, easily assembled, primarycondensation chamber 45, all within the heater at the first end of thecartridge 30 or pod 30 a.

In some embodiments of the device, as illustrated in FIGS. 9A-9L, theheater may encloses at least a first end of the cartridge. The enclosedfirst end of the cartridge may include the heater and the interior fluidstorage compartment. In some embodiments, the heater further comprisesat least one first condensation chamber 45.

FIGS. 9A-9L show diagramed steps that mat be performed to assemble acartomizer and/or mouthpiece. In 9A-9B the fluid storage compartment 32a may be oriented such that the heater inlet 53 faces upward. The heatercontacts 33 may be inserted into the fluid storage compartment. Flexibletabs 33 a may be inserted into the heater contacts 33. In a FIG. 9D theresistive heating element 35 may be wound on to the wick 34. In FIG. 9Ethe wick 34 and heater 35 may be placed on the fluid storagecompartment. One or more free ends of the heater may sit outside theheater contacts. The one or more free ends may be soldered in place,rested in a groove, or snapped into a fitted location. At least afraction of the one or more free ends may be in communication with theheater contacts 33. In a FIG. 9F the heater enclosure 36 may be snappedin place. The heater enclosure 36 may be fitted on the fluid storagecompartment. FIG. 9G shows the heater enclosure 36 is in place on thefluid storage compartment. In FIG. 9H the fluid storage compartment canbe flipped over. In FIG. 9I the mouthpiece 31 can be fitted on the fluidstorage compartment. FIG. 9J shows the mouthpiece 31 in place on thefluid storage compartment. In FIG. 9K an end 49 can be fitted on thefluid storage compartment opposite the mouthpiece. FIG. 9L shows a fullyassembled cartridge 30. FIG. 7B shows an exploded view of the assembledcartridge 30.

Depending on the size of the heater and/or heater chamber, the heatermay have more than one wick 34 and resistive heating element 35.

In some embodiments, the first pair of heater contacts 33 furthercomprises a formed shape that comprises a tab 33 a having a flexiblespring value that extends out of the heater. In some embodiments, thecartridge 30 comprises heater contacts 33 which are inserted into thecartridge receptacle 21 of the device body 20 wherein, the flexible tabs33 a insert into a second pair of heater contacts 22 to complete acircuit with the device body. The first pair of heater contacts 33 maybe a heat sink that absorbs and dissipates excessive heat produced bythe resistive heating element 35. The first pair of heater contacts 33may be a heat shield that protects the heater chamber from excessiveheat produced by the resistive heating element 35. The first pair ofheater contacts may be press-fit to an attachment feature on theexterior wall of the first end of the cartridge. The heater 36 mayenclose a first end of the cartridge and a first end of the fluidstorage compartment 32 a. The heater may comprise a first condensationchamber 45. The heater may comprise at least one additional condensationchamber 45, 45′, 45″, etc. The first condensation chamber may be formedalong an exterior wall of the cartridge.

In still other embodiments of the device, the cartridge may furthercomprise a mouthpiece 31, wherein the mouthpiece comprises at least oneaerosol outlet channel/secondary condensation chamber 46; and at leastone aerosol outlet 47. The mouthpiece may be attached to a second end ofthe cartridge. The second end of the cartridge with the mouthpiece maybe exposed when the cartridge is inserted in the device. The mouthpiecemay comprise more than one second condensation chamber 46, 46′, 46″,etc. The second condensation chamber is formed along an exterior wall ofthe cartridge.

The mouthpiece 31 may enclose the second end of the cartridge andinterior fluid storage compartment. The partially assembled (e.g.,mouthpiece removed) unit may be inverted and filled with a vaporizablefluid through the opposite, remaining (second) open end. Once filled, asnap-on mouthpiece 31 that also closes and seals the second end of thetank is inserted over the end. It also comprises raised internal edges(not shown), and aerosol outlet channel covers 46 a that may slide overthe rails 46 b located on the sides of the second half of the tank,creating aerosol outlet channels/secondary condensation chambers 46. Theaerosol outlet channels/secondary condensation chambers 46 slide overthe end of primary condensation chamber 45, at a transition area 57, tocreate a junction for the vapor leaving the primary chamber and proceedout through the aerosol outlets 47, at the end of the aerosol outletchannels 46 and user-end of the mouthpiece 31.

The cartridge may comprise a first condensation chamber and a secondcondensation chamber 45, 46. The cartridge may comprise more than onefirst condensation chamber and more than one second condensation chamber45, 46, 45′, 46′, etc.

In some embodiments of the device, a first condensation chamber 45 maybe formed along the outside of the cartridge fluid storage compartment31. In some embodiments of the device an aerosol outlet 47 exists at theend of aerosol outlet chamber 46. In some embodiments of the device, afirst and second condensation chamber 45, 46 may be formed along theoutside of one side of the cartridge fluid storage compartment 31. Insome embodiments the second condensation chamber may be an aerosoloutlet chamber. In some embodiments another pair of first and/or secondcondensation chambers 45′, 46′ is formed along the outside of thecartridge fluid storage compartment 31 on another side of the device. Insome embodiments another aerosol outlet 47′ will also exist at the endof the second pair of condensation chambers 45′, 46′.

In any one of the embodiments, the first condensation chamber and thesecond condensation chamber may be in fluid communication as illustratedin FIG. 10C.

In some embodiments, the mouthpiece may comprise an aerosol outlet 47 influid communication with the second condensation chamber 46. Themouthpiece may comprise more than one aerosol outlet 47, 47′ in fluidcommunication with more than one the second condensation chamber 46,46′. The mouthpiece may enclose a second end of the cartridge and asecond end of the fluid storage compartment.

In each of the embodiments described herein, the cartridge may comprisean airflow path comprising: an air inlet passage; a heater; at least afirst condensation chamber; an aerosol outlet chamber, and an outletport. In some of the embodiments described herein, the cartridgecomprises an airflow path comprising: an air inlet passage; a heater; afirst condensation chamber; a secondary condensation chamber; and anoutlet port.

In still other embodiments described herein the cartridge may comprisean airflow path comprising at least one air inlet passage; a heater; atleast one first condensation chamber; at least one secondarycondensation chamber; and at least one outlet port.

As illustrated in FIGS. 10A-10C, an airflow path is created when theuser draws on the mouthpiece 31 to create a suction (e.g., a puff),which essentially pulls air through the channel air inlet opening 50,through the air inlet passage 51, and into the heater chamber 37 throughthe second air passage (tank air inlet hole) 41 at the tank air inlet52, then into the heater inlet 53. At this point, the pressure sensorhas sensed the user's puff, and activated the circuit to the resistiveheating element 35, which in turn, begins to generate vapor from thevapor fluid (e-juice). As air enters the heater inlet 53, it begins tomix and circulate in a narrow chamber above and around the wick 34 andbetween the heater contacts 33, generating heat, and dense, concentratedvapor as it mixes in the flow path 54 created by the sealing structureobstacles 44. FIG. 8A shows a detailed view of the sealing structureobstacles 44. Ultimately the vapor may be drawn, out of the heater alongan air path 55 near the shoulder of the heater and into the primarycondensation chamber 45 where the vapor expands and begins to cool. Asthe expanding vapor moves along the airflow path, it makes a transitionfrom the primary condensation chamber 45 through a transition area 57,creating a junction for the vapor leaving the primary chamber, andentering the second vapor chamber 46, and proceeds out through theaerosol outlets 47, at the end of the mouthpiece 31 to the user.

As illustrated in FIGS. 10A-10C, the device may have a dual set of airinlet passages 50-53, dual first condensation chambers 55/45, dualsecond condensation chambers and aeration channels 57/46, and/or dualaerosol outlet vents 47.

Alternatively, the device may have an airflow path comprising: an airinlet passage 50, 51; a second air passage 41; a heater chamber 37; afirst condensation chamber 45; a second condensation chamber 46; and/oran aerosol outlet 47.

In some cases, the devise may have an airflow path comprising: more thanone air inlet passage; more than one second air passage; a heaterchamber; more than one first condensation chamber; more than one secondcondensation chamber; and more than one aerosol outlet as clearlyillustrated in FIGS. 10A-10C.

In any one of the embodiments described herein, the heater 36 may be influid communication with the internal fluid storage compartment 32 a.

In each of the embodiments described herein, the fluid storagecompartment 32 is in fluid communication with the heater chamber 37,wherein the fluid storage compartment is capable of retaining condensedaerosol fluid, as illustrated in FIGS. 10A, 10C and 14.

In some embodiments of the device, the condensed aerosol fluid maycomprise a nicotine formulation. In some embodiments, the condensedaerosol fluid may comprise a humectant. In some embodiments, thehumectant may comprise propylene glycol. In some embodiments, thehumectant may comprise vegetable glycerin.

In some cases, the cartridge may be detachable from the device body. Insome embodiments, the cartridge receptacle and the detachable cartridgemay form a separable coupling. In some embodiments the separablecoupling may comprise a friction assembly. As illustrated in FIGS.11-14, the device may have a press-fit (friction) assembly between thecartridge pod 30 a and the device receptacle. Additionally, adent/friction capture such as 43 may be utilized to capture the pod 30 ato the device receptacle or to hold a protective cap 38 on the pod, asfurther illustrated in FIG. 8B.

In other embodiments, the separable coupling may comprise a snap-fit orsnap-lock assembly. In still other embodiments the separable couplingmay comprise a magnetic assembly.

In any one of the embodiments described herein, the cartridge componentsmay comprise a snap-fit or snap-lock assembly, as illustrated in FIG. 5.In any one of the embodiments, the cartridge components may be reusable,refillable, and/or recyclable. The design of these cartridge componentslend themselves to the use of such recyclable plastic materials aspolypropylene, for the majority of components.

In some embodiments of the device 10, the cartridge 30 may comprise: afluid storage compartment 32; a heater 36 affixed to a first end with asnap-fit coupling 39 a, 39 b; and a mouthpiece 31 affixed to a secondend with a snap-fit coupling 39 c, 39 d (not shown—but similar to 39 aand 39 b). The heater 36 may be in fluid communication with the fluidstorage compartment 32. The fluid storage compartment may be capable ofretaining condensed aerosol fluid. The condensed aerosol fluid maycomprise a nicotine formulation. The condensed aerosol fluid maycomprise a humectant. The humectant may comprise propylene glycol and/orvegetable glycerin.

Provided herein is a device for generating an inhalable aerosolcomprising: a device body 20 comprising a cartridge receptacle 21 forreceiving a cartridge 30; wherein an interior surface of the cartridgereceptacle forms a first side of an air inlet passage 51 when acartridge comprising a channel integral 40 to an exterior surface isinserted into the cartridge receptacle 21, and wherein the channel formsa second side of the air inlet passage 51.

Provided herein is a device for generating an inhalable aerosolcomprising: a device body 20 comprising a cartridge receptacle 21 forreceiving a cartridge 30; wherein the cartridge receptacle comprises achannel integral to an interior surface and forms a first side of an airinlet passage when a cartridge is inserted into the cartridgereceptacle, and wherein an exterior surface of the cartridge forms asecond side of the air inlet passage 51.

Provided herein is a cartridge 30 for a device for generating aninhalable aerosol 10 comprising: a fluid storage compartment 32; achannel integral 40 to an exterior surface, wherein the channel forms afirst side of an air inlet passage 51; and wherein an internal surfaceof a cartridge receptacle 21 in the device forms a second side of theair inlet passage 51 when the cartridge is inserted into the cartridgereceptacle.

Provided herein is a cartridge 30 for a device for generating aninhalable aerosol 10 comprising a fluid storage compartment 32, whereinan exterior surface of the cartridge forms a first side of an air inletchannel 51 when inserted into a device body 10 comprising a cartridgereceptacle 21, and wherein the cartridge receptacle further comprises achannel integral to an interior surface, and wherein the channel forms asecond side of the air inlet passage 51.

In some embodiments, the cartridge further comprises a second airpassage 41 in fluid communication with the channel 40, wherein thesecond air passage 41 is formed through the material of the cartridge 32from an exterior surface of the cartridge to the internal fluid storagecompartment 32 a.

In some embodiments of the device body cartridge receptacle 21 or thecartridge 30, the integral channel 40 comprises at least one of: agroove; a trough; a depression; a dent; a furrow; a trench; a crease;and a gutter.

In some embodiments of the device body cartridge receptacle 21 or thecartridge 30, the integral channel 40 comprises walls that are eitherrecessed into the surface or protrude from the surface where it isformed.

In some embodiments of the device body cartridge receptacle 21 or thecartridge 30, the internal side walls of the channel 40 form additionalsides of the air inlet passage 51.

Provided herein is a device for generating an inhalable aerosolcomprising: a cartridge comprising; a fluid storage compartment; aheater affixed to a first end comprising; a first heater contact, aresistive heating element affixed to the first heater contact; a devicebody comprising; a cartridge receptacle for receiving the cartridge; asecond heater contact adapted to receive the first heater contact and tocomplete a circuit; a power source connected to the second heatercontact; a printed circuit board (PCB) connected to the power source andthe second heater contact; wherein the PCB is configured to detect theabsence of fluid based on the measured resistance of the resistiveheating element, and turn off the device.

Referring now to FIGS. 13, 14, and 15, in some embodiments, the devicebody further comprises at least one: second heater contact 22 (bestshown in FIG. 6C detail); a battery 23; a printed circuit board 24; apressure sensor 27; and an indicator light 26.

In some embodiments, the printed circuit board (PCB) further comprises:a microcontroller; switches; circuitry comprising a reference resister;and an algorithm comprising logic for control parameters; wherein themicrocontroller cycles the switches at fixed intervals to measure theresistance of the resistive heating element relative to the referenceresistor, and applies the algorithm control parameters to control thetemperature of the resistive heating element.

As illustrated in the basic block diagram of FIG. 17A, the deviceutilizes a proportional-integral-derivative controller or PID controllaw. A PID controller calculates an “error” value as the differencebetween a measured process variable and a desired SetPoint. When PIDcontrol is enabled, power to the coil is monitored to determine whetheror not acceptable vaporization is occurring. With a given airflow overthe coil, more power will be required to hold the coil at a giventemperature if the device is producing vapor (heat is removed from thecoil to form vapor). If power required to keep the coil at the settemperature drops below a threshold, the device indicates that it cannotcurrently produce vapor. Under normal operating conditions, thisindicates that there is not enough liquid in the wick for normalvaporization to occur.

In some embodiments, the micro-controller instructs the device to turnitself off when the resistance exceeds the control parameter thresholdindicating that the resistive heating element is dry.

In still other embodiments, the printed circuit board further compriseslogic capable of detecting the presence of condensed aerosol fluid inthe fluid storage compartment and is capable of turning off power to theheating contact(s) when the condensed aerosol fluid is not detected.When the microcontroller is running the PID temperature controlalgorithm 70, the difference between a set point and the coiltemperature (error) is used to control power to the coil so that thecoil quickly reaches the set point temperature, (e.g., between 200° C.and 400° C.). When the over-temperature algorithm is used, power isconstant until the coil reaches an over-temperature threshold, (e.g.,between 200° C. and 400° C.); (FIG. 17A applies: set point temperatureis over-temperature threshold; constant power until error reaches 0).

The essential components of the device used to control the resistiveheating element coil temperature are further illustrated in the circuitdiagram of FIG. 17B. Wherein, BATT 23 is the battery; MCU 72 is themicrocontroller; Q1 (76) and Q2 (77) are P-channel MOSFETs (switches);R_COIL 74 is the resistance of the coil. R_REF 75 is a fixed referenceresistor used to measure R_COIL 74 through a voltage divider 73.

The battery powers the microcontroller. The microcontroller turns on Q2for 1 ms every 100 ms so that the voltage between R_REF and R_COIL (avoltage divider) may be measured by the MCU at V_MEAS. When Q2 is off,the control law controls Q1 with PWM (pulse width modulation) to powerthe coil (battery discharges through Q1 and R_COIL when Q1 is on).

In some embodiments of the device, the device body further comprises atleast one: second heater contact; a power switch; a pressure sensor; andan indicator light.

In some embodiments of the device body, the second heater contact 22 maycomprise: a female receptacle; or a male contact, or both, a flexiblecontact; or copper alloy or another electrically conductive material.

In some embodiments of the device body, the battery supplies power tothe second heater contact, pressure sensor, indicator light and theprinted circuit board. In some embodiments, the battery is rechargeable.In some embodiments, the indicator light 26 indicates the status of thedevice and/or the battery or both.

In some embodiments of the device, the first heater contact and thesecond heater contact complete a circuit that allows current to flowthrough the heating contacts when the device body and detachablecartridge are assembled, which may be controlled by an on/off switch.Alternatively, the device can be turned on an off by a puff sensor. Thepuff sensor may comprise a capacitive membrane. The capacitive membranemay be similar to a capacitive membrane used in a microphone.

In some embodiments of the device, there is also an auxiliary chargingunit for recharging the battery 23 in the device body. As illustrated inFIGS. 16A-16C, the charging unit 60, may comprise a USB device with aplug for a power source 63 and protective cap 64, with a cradle 61 forcapturing the device body 20 (with or without the cartridge installed).The cradle may further comprise either a magnet or a magnetic contact 62to securely hold the device body in place during charging. Asillustrated in FIG. 6B, the device body further comprises a matingcharging contact 28 and a magnet or magnetic contact 29 for theauxiliary charging unit. FIG. 16C is an illustrative example of thedevice 20 being charged in a power source 65 (laptop computer ortablet).

In some cases the microcontroller on the PCB may be configured tomonitor the temperature of the heater such that the vaporizable materialis heated to a prescribed temperature. The prescribed temperature may bean input provided by the user. A temperature sensor may be incommunication with the microcontroller to provide an input temperatureto the microcontroller for temperature regulation. A temperature sensormay be a thermistor, thermocouple, thermometer, or any other temperaturesensors. In some cases, the heating element may simultaneously performas both a heater and a temperature sensor. The heating element maydiffer from a thermistor by having a resistance with a relatively lowerdependence on temperature. The heating element may comprise a resistancetemperature detector.

The resistance of the heating element may be an input to themicrocontroller. In some cases, the resistance may be determined by themicrocontroller based on a measurement from a circuit with a resistorwith at least one known resistance, for example, a Wheatstone bridge.Alternatively, the resistance of the heating element may be measuredwith a resistive voltage divider in contact with the heating element anda resistor with a known and substantially constant resistance. Themeasurement of the resistance of the heating element may be amplified byan amplifier. The amplifier may be a standard op amp or instrumentationamplifier. The amplified signal may be substantially free of noise. Insome cases, a charge time for a voltage divider between the heatingelement and a capacitor may be determined to calculate the resistance ofthe heating element. In some cases, the microcontroller must deactivatethe heating element during resistance measurements. The resistance ofthe heating element may be a function of the temperature of the heatingelement such that the temperature may be directly determined fromresistance measurements. Determining the temperature directly from theheating element resistance measurement rather than from an additionaltemperature sensor may generate a more accurate measurement becauseunknown contact thermal resistance between the temperature sensor andthe heating element is eliminated. Additionally, the temperaturemeasurement may be determined directly and therefore faster and withouta time lag associated with attaining equilibrium between the heatingelement and a temperature sensor in contact with the heating element.

FIG. 17C is another example of a PID control block diagram similar tothat shown in FIG. 17A, and FIG. 17D is an example of a resistancemeasurement circuit used in this PID control scheme. In FIG. 17C, theblock diagram includes a measurement circuit that can measure theresistance of the resistive heater (e.g., coil) and provide an analogsignal to the microcontroller, a device temperature, which can bemeasured directly by the microcontroller and/or input into themicrocontroller, and an input from a sensor (e.g., a pressure sensor, abutton, or any other sensor) that may be used by the microcontroller todetermine when the resistive heart should be heated, e.g., when the useris drawing on the device or when the device is scheduled to be set at awarmer temperature (e.g., a standby temperature).

In FIG. 17C, a signal from the measurement circuit goes directly to themicrocontroller and to a summing block. In the measurement circuit, anexample of which is shown in FIG. 17D (similar to the one shown in FIG.17B), signal from the measurement circuit are fed directly to themicrocontroller. The summing block in FIG. 17C is representative of thefunction which may be performed by the microcontroller when the deviceis heating; the summing block may show that error (e.g., in this case, atarget Resistance minus a measured resistance of the resistive heater)is used by a control algorithm to calculate the power to be applied tothe coil until the next coil measurement is taken.

In the example shown in FIGS. 17C-17D, signal from the measurementcircuit may also go directly to the microcontroller in FIG. 17C; theresistive heater may be used to determine a baseline resistance (alsoreferred to herein as the resistance of the resistive hater at anambient temperature), when the device has not been heating the resistiveheater, e.g., when some time has passed since the device was lastheating. Alternatively or additionally, the baseline resistance may bedetermined by determining when coil resistance is changing with time ata rate that is below some stability threshold. Thus, resistancemeasurements of the coil may be used to determine a baseline resistancefor the coil at ambient temperature.

A known baseline resistance may be used to calculate a target resistancethat correlates to a target rise in coil temperature. The baseline(which may also be referred to as the resistance of the resistive heaterat ambient temperature) may also be used to calculate the targetresistance. The device temperature can be used to calculate an absolutetarget coil temperature as opposed to a target temperature rise. Forexample, a device temperature may be used to calculate absolute targetcoil temperature for more precise temperature control.

The circuit shown in FIG. 17B is one embodiment of a resistancemeasurement circuit comprising a voltage divider using a presetreference resistance. For the reference resistor approach (alternativelyreferred to as a voltage divider approach) shown in 17B, the referenceresistor may be roughly the same resistance as the coil at targetresistance (operating temperature). For example, this may be 1-2 Ohms.The circuit shown in FIG. 17D is another variation of a resistancemeasurement (or comparison) circuit. As before, in this example, theresistance of the heating element may be a function of the temperatureof the heating element such that the temperature may be directlydetermined from resistance measurements. The resistance of the heatingelement is roughly linear with the temperature of the heating element.

In FIG. 17D, the circuit includes a Wheatstone bridge connected to adifferential op amp circuit. The measurement circuit is powered when Q2is held on via the RM_PWR signal from the microcontroller (RM=ResistanceMeasurement). Q2 is normally off to save battery life. In general, theapparatuses described herein stop applying power to the resistive heaterto measure the resistance of the resistive heater. In FIG. 17D, whenheating, the device must stop heating periodically (turn Q1 off) tomeasure coil resistance. One voltage divider in the bridge is betweenthe Coil and R1, the other voltage divider is between R2 and R3 andoptionally R4, R5, and R6. R4, R5, and R6 are each connected to opendrain outputs from the microcontroller so that the R3 can be in parallelwith any combination of R4, R5, and R6 to tune the R2/R3 voltagedivider. An algorithm tunes the R2/R3 voltage divider via open draincontrol of RM_SCALE_0, RM_SCALE_1, and RM_SCALE_2 so that the voltage atthe R2/R3 divider is just below the voltage of the R_COIL/R1 divider, sothat the output of the op amp is between positive battery voltage andground, which allows small changes in coil resistance to result inmeasureable changes in the op amp's output voltage. U2, R7, R8, R9, andR10 comprise the differential op amp circuit. As is standard indifferential op amp circuits, R9/R7=R10/R8, R9>>R7, and the circuit hasa voltage gain, A=R9/R7, such that the op amp outputs HM_OUT=A(V⁺−V⁻)when 0≦A(V⁺−V⁻)≦V_BAT, where V⁺ is the R_COIL/R1 divider voltage, V⁻ isthe tuned R2/R3 divider voltage, and V_BAT is the positive batteryvoltage.

In this example, the microcontroller performs an analog to digitalconversion to measure HM_OUT, and then based on the values of R1 throughR10 and the selected measurement scale, calculates resistance of thecoil. When the coil has not been heated for some amount of time (e.g.,greater than 10 sec, 20 sec, 30 sec, 1 min, 2 min, 3 min, 4 min, 5 min,6 min, 7 min, 8 min, 9 min, 10 min, 15 min, 20 min, 30 min, etc.) and/orthe resistance of the coil is steady, the microcontroller may savecalculated resistance as the baseline resistance for the coil. A targetresistance for the coil is calculated by adding a percentage change ofbaseline resistance to the baseline resistance. When the microcontrollerdetects via the pressure sensor that the user is drawing from thedevice, it outputs a PWM signal on HEATER to power the coil through Q1.PWM duty cycle is always limited to a max duty cycle that corresponds toa set maximum average power in the coil calculated using battery voltagemeasurements and coil resistance measurements. This allows forconsistent heat-up performance throughout a battery discharge cycle. APID control algorithm uses the difference between target coil resistanceand measured coil resistance to set PWM duty cycle (limited by max dutycycle) to hold measured resistance at target resistance. The PID controlalgorithm holds the coil at a controlled temperature regardless of airflow rate and wicking performance to ensure a consistent experience(e.g., vaporization experience, including “flavor”) across the fullrange of use cases and allow for higher power at faster draw rates. Ingeneral, the control law may update at any appropriate rate. Forexample, in some variations, the control law updates at 20 Hz. In thisexample, when heating, PWM control of Q1 is disabled and Q1 is held offfor 2 ms every 50 ms to allow for stable coil resistance measurements.In another variation, the control law may update at 250-1000 Hz.

In the example shown in FIG. 17D, the number of steps between max andmin measureable analog voltage may be controlled by the configuration.For example, precise temperature control (+/−1° C. or better) maybeachieved with a few hundred steps between measured baseline resistanceand target resistance. In some variations, the number of steps may beapproximately 4096. With variations in resistance between cartridges(e.g., +/−10% nominal coil resistance) and potential running changes tonominal cartridge resistance, it may be advantages to have severalnarrower measurement scales so that resistance can be measured at higherresolution than could be achieved if one fixed measurement scale had tobe wide enough to measure all cartridges that a device might see. Forexample, R4, R5, and R6 may have values that allow for eight overlappingresistance measurement scales that allow for roughly five times thesensitivity of a single fixed scale covering the same range ofresistances that are measurable by eight scales combined. More or lessthan eight measurement ranges may be used.

For example, in the variation shown in FIG. 17D, in some instances themeasurement circuit may have a total range of 1.31-2.61 Ohm and asensitivity of roughly 0.3 mOhm, which may allow for temperature settingincrements and average coil temperature control to within +/−0.75° C.(e.g., a nominal coil resistance*TCR=1.5 Ohm*0.00014/° C.=0.21 mOhm/°C., 0.3 mOhm/(0.21 mOhm/° C.)=1.4° C. sensitivity). In some variations,R_COIL is 1.5 Ohm nominally, R1=100 Ohm, R2=162 Ohm, R3=10 kOhm, R4=28.7kOhm, R5=57.6 kOhm, R6=115 kOhm, R7=R9=2 kOhm, R8=R10=698 kOhm.

As mentioned above, heater resistance is roughly linear withtemperature. Changes in heater resistance may be roughly proportional tochanges in temperature. With a coil at some resistance, R_(baseline), atsome initial temperature, ΔT=(R_(coil)/R_(baseline)−1)/TCR is a goodapproximation of coil temperature rise. Using an amplified Wheatstonebridge configuration similar to that shown in FIG. 17D, the device maycalculate target resistance using baseline resistance and a fixed targetpercentage change in resistance, 4.0%. For coils with TCR of, as anexample, 0.00014/° C., this may correspond to a 285° C. temperature rise(e.g., 0.04/(0.00014/° C.)=285° C.).

In general, the device doesn't need to calculate temperature; thesecalculations can be done beforehand, and the device can simply use atarget percentage change in resistance to control temperature. For somebaseline resistance, coil TCR, and target temperature change, targetheater resistance may be: R_(target)=R_(baseline) (1+TCR*ΔT). Solved forΔT, this is ΔT=(R_(target)/R_(baseline)−1)/TCR. Some device variationsmay calculate and provide (e.g., display, transmit, etc.) actualtemperature so users can see actual temperatures during heat up or set atemperature in the device instead of setting a target percentage changein resistance.

Alternatively or additionally, the device may use measured ambienttemperature and a target temperature (e.g., a temperature set point) tocalculate a target resistance that corresponds to the targettemperature. The target resistance may be determined from a baselineresistance at ambient temperature, coil TCR, target temperature, andambient temperature. For example, a target heater resistance may beexpressed as R_(target)/R_(baseline)(1+TCR*(T_(set)−T_(amb))). Solvedfor T_(set), this gives:T_(set)=(R_(target)/R_(baseline)−1)/TCR+T_(amb). Some device variationsmay calculate and provide (e.g., display, transmit, etc.) actualtemperature so users can see actual temperatures during heat up or set atemperature in the device instead of setting a target resistance ortarget percentage change in resistance.

For the voltage divider approach, if R_(reference) is sufficiently closeto R_(baseline), temperature change is approximatelyΔT=(R_(coil)/R_(reference)−R_(baseline)/R_(reference))/TCR.

As mentioned above, any of the device variations described herein may beconfigured to control the temperature only after a sensor indicates thatvaporization is required. For example, a pressure sensor (e.g., “puffsensor”) may be used to determine when the coil should be heated. Thissensor may function as essentially an on off switch for heating underPID control. Additionally, in some variations, the sensor may alsocontrol baseline resistance determination. For example baselineresistance may be prevented until at least some predetermined timeperiod (e.g., 10 sec, 15 sec, 20 sec, 30 sec, 45 sec, 1 min, 2 min,etc.) after the last puff.

Provided herein is a device for generating an inhalable aerosolcomprising: a cartridge comprising a first heater contact; a device bodycomprising; a cartridge receptacle for receiving the cartridge; a secondheater contact adapted to receive the first heater contact and tocomplete a circuit; a power source connected to the second heatercontact; a printed circuit board (PCB) connected to the power source andthe second heater contact; and a single button interface; wherein thePCB is configured with circuitry and an algorithm comprising logic for achild safety feature.

In some embodiments, the algorithm requires a code provided by the userto activate the device. In some embodiments; the code is entered by theuser with the single button interface. In still further embodiments thesingle button interface is the also the power switch.

Provided herein is a cartridge 30 for a device 10 for generating aninhalable aerosol comprising: a fluid storage compartment 32; a heater36 affixed to a first end comprising: a heater chamber 37, a first pairof heater contacts 33, a fluid wick 34, and a resistive heating element35 in contact with the wick; wherein the first pair of heater contacts33 comprise thin plates affixed about the sides of the heater chamber37, and wherein the fluid wick 34 and resistive heating element 35 aresuspended there between.

Depending on the size of the heater or heater chamber, the heater mayhave more than one wick 34, 34′ and resistive heating element 35, 35′.

In some embodiments, the first pair of heater contacts further comprisea formed shape that comprises a tab 33 a having a flexible spring valuethat extends out of the heater 36 to complete a circuit with the devicebody 20.

In some embodiments, the heater contacts 33 are configured to mate witha second pair of heater contacts 22 in a cartridge receptacle 21 of thedevice body 20 to complete a circuit.

In some embodiments, the first pair of heater contacts is also a heatsink that absorbs and dissipates excessive heat produced by theresistive heating element.

In some embodiments, the first pair of heater contacts is a heat shieldthat protects the heater chamber from excessive heat produced by theresistive heating element.

Provided herein is a cartridge 30 for a device for generating aninhalable aerosol 10 comprising: a heater 36 comprising; a heaterchamber 37, a pair of thin plate heater contacts 33 therein, a fluidwick 34 positioned between the heater contacts 33, and a resistiveheating element 35 in contact with the wick; wherein the heater contacts33 each comprise a fixation site 33 c wherein the resistive heatingelement 35 is tensioned there between.

As will be obvious to one skilled in the art after reviewing theassembly method illustrated in FIG. 9, the heater contacts 33 simplysnap or rest on locator pins on either side of the air inlet 53 on thefirst end of the cartridge interior fluid storage compartment, creatinga spacious vaporization chamber containing the at least one wick 34 andat least one heating element 35.

Provided herein is a cartridge 30 for a device for generating aninhalable aerosol 10 comprising a heater 36 attached to a first end ofthe cartridge.

In some embodiments, the heater encloses a first end of the cartridgeand a first end of the fluid storage compartment 32, 32 a.

In some embodiments, the heater comprises a first condensation chamber45.

In some embodiments, the heater comprises more than one firstcondensation chamber 45, 45′.

In some embodiments, the condensation chamber is formed along anexterior wall of the cartridge 45 b.

As noted previously, and described in FIGS. 10A, 10B and 10C, theairflow path through the heater and heater chamber generates vaporwithin the heater circulating air path 54, which then exits through theheater exits 55 into a first (primary) condensation chamber 45, which isformed by components of the tank body comprising the primarycondensation channel/chamber rails 45 b, the primary condensationchannel cover 45 a, (the outer side wall of the heater enclosure).

Provided herein is a cartridge 30 for a device for generating aninhalable aerosol 10 comprising a fluid storage compartment 32 and amouthpiece 31, wherein the mouthpiece is attached to a second end of thecartridge and further comprises at least one aerosol outlet 47.

In some embodiments, the mouthpiece 31 encloses a second end of thecartridge 30 and a second end of the fluid storage compartment 32, 32 a.

Additionally, as clearly illustrated in FIG. 10C in some embodiments themouthpiece also contains a second condensation chamber 46 prior to theaerosol outlet 47, which is formed by components of the tank body 32comprising the secondary condensation channel/chamber rails 46 b, thesecond condensation channel cover 46 a, (the outer side wall of themouthpiece). Still further, the mouthpiece may contain yet anotheraerosol outlet 47′ and another (second) condensation chamber 46′ priorto the aerosol outlet, on another side of the cartridge.

In other embodiments, the mouthpiece comprises more than one secondcondensation chamber 46, 46′.

In some preferred embodiments, the second condensation chamber is formedalong an exterior wall of the cartridge 46 b.

In each of the embodiments described herein, the cartridge 30 comprisesan airflow path comprising: an air inlet channel and passage 40, 41, 42;a heater chamber 37; at least a first condensation chamber 45; and anoutlet port 47. In some of the embodiments described herein, thecartridge 30 comprises an airflow path comprising: an air inlet channeland passage 40, 41, 42; a heater chamber 37; a first condensationchamber 45; a second condensation chamber 46; and an outlet port 47.

In still other embodiments described herein the cartridge 30 maycomprise an airflow path comprising at least one air inlet channel andpassage 40, 41, 42; a heater chamber 37; at least one first condensationchamber 45; at least one second condensation chamber 46; and at leastone outlet port 47.

In each of the embodiments described herein, the fluid storagecompartment 32 is in fluid communication with the heater 36, wherein thefluid storage compartment is capable of retaining condensed aerosolfluid.

In some embodiments of the device, the condensed aerosol fluid comprisesa nicotine formulation. In some embodiments, the condensed aerosol fluidcomprises a humectant. In some embodiments, the humectant comprisespropylene glycol. In some embodiments, the humectant comprises vegetableglycerin.

Provided herein is a cartridge 30 for a device for generating aninhalable aerosol 10 comprising: a fluid storage compartment 32; aheater 36 affixed to a first end; and a mouthpiece 31 affixed to asecond end; wherein the heater comprises a first condensation chamber 45and the mouthpiece comprises a second condensation chamber 46.

In some embodiments, the heater comprises more than one firstcondensation chamber 45, 45′ and the mouthpiece comprises more than onesecond condensation chamber 46, 46′.

In some embodiments, the first condensation chamber and the secondcondensation chamber are in fluid communication. As illustrated in FIG.10C, the first and second condensation chambers have a common transitionarea 57, 57′, for fluid communication.

In some embodiments, the mouthpiece comprises an aerosol outlet 47 influid communication with the second condensation chamber 46.

In some embodiments, the mouthpiece comprises two or more aerosoloutlets 47, 47′.

In some embodiments, the mouthpiece comprises two or more aerosoloutlets 47, 47′ in fluid communication with the two or more secondcondensation chambers 46, 46′.

In any one of the embodiments, the cartridge meets ISO recyclingstandards.

In any one of the embodiments, the cartridge meets ISO recyclingstandards for plastic waste.

And in still other embodiments, the plastic components of the cartridgeare composed of polylactic acid (PLA), wherein the PLA components arecompostable and or degradable.

Provided herein is a device for generating an inhalable aerosol 10comprising a device body 20 comprising a cartridge receptacle 21; and adetachable cartridge 30; wherein the cartridge receptacle and thedetachable cartridge form a separable coupling, and wherein theseparable coupling comprises a friction assembly, a snap-fit assembly ora magnetic assembly.

In other embodiments of the device, the cartridge is a detachableassembly. In any one of the embodiments described herein, the cartridgecomponents may comprise a snap-lock assembly such as illustrated by snapfeatures 39 a and 39 b. In any one of the embodiments, the cartridgecomponents are recyclable.

Provided herein is a method of fabricating a device for generating aninhalable aerosol comprising: providing a device body comprising acartridge receptacle; and providing a detachable cartridge; wherein thecartridge receptacle and the detachable cartridge form a separablecoupling comprising a friction assembly, a snap-fit assembly or amagnetic assembly when the cartridge is inserted into the cartridgereceptacle.

Provided herein is a method of making a device 10 for generating aninhalable aerosol comprising: providing a device body 20 with acartridge receptacle 21 comprising one or more interior couplingsurfaces 21 a, 21 b, 21 c . . . ; and further providing a cartridge 30comprising: one or more exterior coupling surfaces 36 a, 36 b, 36 c, . .. , a second end and a first end; a tank 32 comprising an interior fluidstorage compartment 32 a; at least one channel 40 on at least oneexterior coupling surface, wherein the at least one channel forms oneside of at least one air inlet passage 51, and wherein at least oneinterior wall of the cartridge receptacle forms at least one side oneside of at least one air inlet passage 51when the detachable cartridgeis inserted into the cartridge receptacle.

FIG. 9 provides an illustrative example of a method of assembling such adevice.

In some embodiments of the method, the cartridge 30 is assembled with aprotective removable end cap 38 to protect the exposed heater contacttabs 33 a protruding from the heater 36.

Provided herein is a method of fabricating a cartridge for a device forgenerating an inhalable aerosol comprising: providing a fluid storagecompartment; affixing a heater to a first end with a snap-fit coupling;and affixing a mouthpiece to a second end with a snap-fit coupling.

Provided herein is a cartridge 30 for a device for generating aninhalable aerosol 10 with an airflow path comprising: a channel 50comprising a portion of an air inlet passage 51; a second air passage 41in fluid communication with the channel; a heater chamber 37 in fluidcommunication with the second air passage; a first condensation chamber45 in fluid communication with the heater chamber; a second condensationchamber 46 in fluid communication with the first condensation chamber;and an aerosol outlet 47 in fluid communication with second condensationchamber.

Provided herein is a device 10 for generating an inhalable aerosoladapted to receive a removable cartridge 30, wherein the cartridgecomprises a fluid storage compartment or tank 32; an air inlet 41; aheater 36, a protective removable end cap 38, and a mouthpiece 31.

Charging

In some cases, the vaporization device may comprise a power source. Thepower source may be configured to provide power to a control system, oneor more heating elements, one or more sensors, one or more lights, oneor more indicators, and/or any other system on the electronic cigarettethat requires a power source. The power source may be an energy storagedevice. The power source may be a battery or a capacitor. In some cases,the power source may be a rechargeable battery.

The battery may be contained within a housing of the device. In somecases the battery may be removed from the housing for charging.Alternatively, the battery may remain in the housing while the batteryis being charged. Two or more charge contact may be provided on anexterior surface of the device housing. The two or more charge contactsmay be in electrical communication with the battery such that thebattery may be charged by applying a charging source to the two or morecharge contacts without removing the battery from the housing.

FIG. 18 shows a device 1800 with charge contacts 1801. The chargecontacts 1801 may be accessible from an exterior surface of a devicehousing 1802. The charge contacts 1801 may be in electricalcommunication with an energy storage device (e.g., battery) inside ofthe device housing 1802. In some cases, the device housing may notcomprise an opening through which the user may access components in thedevice housing. The user may not be able to remove the battery and/orother energy storage device from the housing. In order to open thedevice housing a user must destroy or permanently disengage the chargecontacts. In some cases, the device may fail to function after a userbreaks open the housing.

FIG. 19 shows an exploded view of a charging assembly 1900 in anelectronic vaporization device. The housing (not shown) has been removedfrom the exploded view in FIG. 19. The charge contact pins 1901 may bevisible on the exterior of the housing. The charge contact pins 1901 maybe in electrical communication with a power storage device of theelectronic vaporization device. When the device is connected to a powersource (e.g., during charging of the device) the charging pins mayfacilitate electrical communication between the power storage deviceinside of the electronic vaporization device and the power sourceoutside of the housing of the vaporization device. The charge contactpins 1901 may be held in place by a retaining bezel 1902. The chargecontact pins 1901 may be in electrical communication with a charger flex1903. The charging pins may contact the charger flex such that a needfor soldering of the charger pins to an electrical connection to be inelectrical communication with the power source may be eliminated. Thecharger flex may be soldered to a printed circuit board (PCB). Thecharger flex may be in electrical communication with the power storagedevice through the PCB. The charger flex may be held in place by a bentspring retainer 1904.

FIG. 20 shows the bent spring retainer in an initial position 2001 and adeflected position 2002. The bent spring retainer may hold the retainingbezel in a fixed location. The bent spring retainer may deflect only inone direction when the charging assembly is enclosed in the housing ofthe electronic vaporization device.

FIG. 21 shows a location of the charger pins 2101 when the electronicvaporization device is fully assembled with the charging pins 2101contact the charging flex 2102. When the device is fully assembled atleast a portion of the retaining bezel may be fitted in an indentation2103 on the inside of the housing 2104. In some cases, disassembling theelectronic vaporization device may destroy the bezel such that thedevice cannot be reassembled after disassembly.

A user may place the electronic smoking device in a charging cradle. Thecharging cradle may be a holder with charging contact configured to mateor couple with the charging pins on the electronic smoking device toprovide charge to the energy storage device in the electronicvaporization device from a power source (e.g., wall outlet, generator,and/or external power storage device). FIG. 22 shows a device 2302 in acharging cradle 2301. The charging cable may be connected to a walloutlet, USB, or any other power source. The charging pins (not shown) onthe device 2302 may be connected to charging contacts (not shown) on thecharging cradle 2301. The device may be configured such that when thedevice is placed in the cradle for charging a first charging pin on thedevice may contact a first charging contact on the charging cradle and asecond charging pin on the device may contact a second charging contacton the charging cradle or the first charging pin on the device maycontact a second charging contact on the charging cradle and the secondcharging pin on the device may contact the first charging contact on thecharging cradle. The charging pins on the device and the chargingcontacts on the cradle may be in contact in any orientation. Thecharging pins on the device and the charging contacts on the cradle maybe agnostic as to whether they are current inlets or outlets. Each ofthe charging pins on the device and the charging contacts on the cradlemay be negative or positive. The charging pins on the device may bereversible.

FIG. 23 shows a circuit 2400 that may permit the charging pins on thedevice to be reversible. The circuit 2400 may be provided on a PCB inelectrical communication with the charging pins. The circuit 2400 maycomprise a metal-oxide-semiconductor field-effect transistor (MOSFET) Hbridge. The MOSFET H bridge may rectify a change in voltage across thecharging pins when the charging pins are reversed from a firstconfiguration where in a first configuration the device is placed in thecradle for charging with the first charging pin on the device in contactwith the first charging contact on the charging cradle to a secondcharging pin on the device in contact with the second charging contacton the charging cradle to a second configuration where the firstcharging pin on the device is in contact with the second chargingcontact on the charging cradle and the second charging pin on the deviceis in contact with the first charging contact on the charging cradle.The MOSFET H bridge may rectify the change in voltage with an efficientcurrent path.

As shown in FIG. 23 the MOSFET H bridge may comprise two or moren-channel MOSFETs and two or more p-channel MOSFETs. The n-channel andp-channel MOSFETs may be arranged in an H bridge. Sources of p-channelsMOSFETs (Q1 and Q3) may be in electrical communication. Similarly,sources of n-channel FETs (Q2 and Q4) may be in electricalcommunication. Drains of pairs of n and p MOSFETs (Q1 with Q2 and Q3with Q4) may be in electrical communication. TA common drain from one nand p pair may be in electrical communication with one or more gates ofthe other n and p pair and/or vice versa. Charge contacts (CH1 and CH2)may be in electrical communication to common drains separately. A commonsource of the n MOSFETs may be in electrical communication to PCB ground(GND). The common source of the p MOSFETs may be in electricalcommunication with the PCB's charge controller input voltage (CH+). WhenCH1 voltage is greater than CH2 voltage by the MOSFET gate thresholdvoltages, Q1 and Q4 may be “on,” connecting CH1 to CH+ and CH2 to GND.When CH2 voltage is greater than CH1 voltage by the FET gate thresholdvoltages, Q2 and Q3 may be “on,” connecting CH1 to GND and CH2 to CH+.For example, whether there is 9V or −9V across CH1 to CH2, CH+ will be9V above GND. Alternatively, a diode bridge could be used, however theMOSFET bridge may be more efficient compared to the diode bridge.

In some cases the charging cradle may be configured to be a smartcharger. The smart charger may put the battery of the device in serieswith a USB input to charge the device at a higher current compared to atypical charging current. In some cases, the device may charge at a rateup to about 2 amps (A), 4 A, 5 A, 6 A, 7 A, 10 A, or 15 A. In somecases, the smart charger may comprise a battery, power from the batterymay be used to charge the device battery. When the battery in the smartcharger has a charge below a predetermined threshold charge, the smartcharger may simultaneously charge the battery in the smart charger andthe battery in the device.

Cartridge/Vaporizer Attachment

Any of the cartridges described herein may be adapted for securelycoupling with an electronic inhalable aerosol device (“vaporizer”) asdiscussed above. In particular described herein are cartridge designsthat address the unrecognized problem of maintaining adequate electricalcontact between a mouthpiece-containing cartridge and a rectangularvaporizer coupling region, particularly when the mouthpiece is held in auser's mouth.

Any of the cartridges described herein may be particularly well adaptedfor securing to a vaporizer by including a base region that mates withthe rectangular coupling region of the vaporizer, where the base unitfits into a rectangular opening that is between 13-14 mm deep, 4.5-5.5mm wide, and 13-14 mm long. The base having generally includes a bottomsurface having a first electrical contact and a second electricalcontact. In particular, any of the cartridges described herein mayinclude a first locking gap on a first lateral surface of the base, anda second locking gap on a second lateral surface of the base that isopposite first lateral surface.

For example FIGS. 24A and 24B illustrate another variation of acartridge similar to that shown in FIGS. 7A-15, discussed above, havinga base region 2401 with at least one locking gap 2404 on the first minorlateral wall 2407. A second locking gap (not shown) may be present onthe opposite minor lateral wall. One or both major lateral walls 2418may include a detent 2421. Any of these cartridges may also include amouthpiece 2409, which may be at an end that is opposite of the bottom2422 of the cartridge, on which a pair of tabs (electrodes 2411) arepositioned, shown in FIG. 24A (as previously described, above) bent overthe distal end of the cartridge. FIGS. 25A and 25B show front and sideviews, respectively, of this example.

In FIGS. 24A-25B the locking gaps 2404, 2404′ on either side are shownas channels in the side (lateral) walls. They may extend across theentire side wall, parallel to the bottom as shown, or they may extendonly partially through and may preferably be centered relative to thewidth of the wall. In other variations the locking gap may be a divot,pit, opening, or hole (though not into the internal volume holding thevaporizable material).

In general, the inventors have found that the vertical position of thelocking gap may be important in maintaining the stability of thecartridge in the vaporizer, particularly in cartridges having arectangular base region that is longer than 10 mm. Optimally, thelocking gap may be between about 1 and 5 mm from the bottom of the baseregion, and more specifically, between about 3 and 4 mm (e.g.,approximately 3.3 mm), as shown in FIG. 26A which indicates exemplarydimensions for the section through FIG. 26B.

The cartridges shown in FIGS. 24A-24B also include a detent 2421 that ispositioned between about 7 and 11 mm up from the bottom of thecartridge. The detent may help hold the cartridge base in the vaporizer,and may cooperate with the locking gap, but is optional (and shown indashed lines in FIGS. 2A-25B.

In FIGS. 24A-25B the cartridge base is also transparent, and shows aninternal air channel (cannula 2505).

FIGS. 27A-27B show another example of a vaporizer including a batteryand control circuitry. FIGS. 27A and 27B also illustrate the matingregion 2704. In this example, the mating region includes two detents2706 that may mate with the locking gaps on the cartridge when it isinserted into the vaporizer. Exemplary dimensions for the mating regionare shown. In this example the locking detents (which complement thelocking gaps on the cartridge) are indentations that project into themating region. These locking determent may be a ridge, pin, or otherprojection (including spring-loaded members).

FIGS. 28A-28D show an example of a vaporizer 2803 into which a cartridge2801 has been securely loaded. In FIG. 28A the cartridge has beensnapped into position so that the locking gaps of the cartridge engagewith the locking detents in the vaporizer. FIG. 28B is side view andFIG. 28C show a sectional view; an enlarged portion of the sectionalview is shown in FIG. 28D, showing the base of the cartridge seated inthe mating region of the vaporizer. With the cartridge secured as shown,good electrical contact 2805 may be maintained.

Although the cartridges shown in FIGS. 24A-28D are similar, and includea proximal mouthpiece and distal base that are nearly equivalent insize, with the reservoir for the vaporizable material between them andthe wick, resistive heater, heating chamber and electrodes at the distalmost end (near the bottom of the base), many other cartridgeconfigurations are possible while still securely seating into avaporizer having the same vaporizer mating region shown in FIGS.28A-28B. For example, FIGS. 29A-29D illustrate alternative variations ofcartridges having similar electrode. In FIG. 29A the base regionincludes two projecting feet that include locking gaps, and theelectrodes on the base (not shown) connect via electrical traces (e.g.wires, etc.) to a heating element, wick and the reservoir nearer to thedistal end (not visible).

In FIG. 29B the base extends further than 11 mm (e.g., 20-30 mm) and mayhouse the reservoir (fluid storage compartment). Similarly in FIG. 29Cthe base region is the same as in FIG. 29B, but the more proximalportion is enlarged. In FIG. 29D the fluid non-base portion of thecartridge (more proximal than the base region) may have a differentdimension. All of the variations shown in FIGS. 29A-29D, as in thevariations shown in FIG. 24A-25B, may mate with the same vaporizer, andbecause of the dimensions of the base region, may be securely held andmaintain electrical contact, even when a user is holding the device intheir mouth.

When a feature or element is herein referred to as being “on” anotherfeature or element, it can be directly on the other feature or elementor intervening features and/or elements may also be present. Incontrast, when a feature or element is referred to as being “directlyon” another feature or element, there are no intervening features orelements present. It will also be understood that, when a feature orelement is referred to as being “connected”, “attached” or “coupled” toanother feature or element, it can be directly connected, attached orcoupled to the other feature or element or intervening features orelements may be present. In contrast, when a feature or element isreferred to as being “directly connected”, “directly attached” or“directly coupled” to another feature or element, there are nointervening features or elements present. Although described or shownwith respect to one embodiment, the features and elements so describedor shown can apply to other embodiments. It will also be appreciated bythose of skill in the art that references to a structure or feature thatis disposed “adjacent” another feature may have portions that overlap orunderlie the adjacent feature.

Terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention.For example, as used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification,specify the presence of stated features, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, steps, operations, elements, components, and/orgroups thereof. As used herein, the term “and/or” includes any and allcombinations of one or more of the associated listed items and may beabbreviated as “/”.

Spatially relative terms, such as “under”, “below”, “lower”, “over”,“upper” and the like, may be used herein for ease of description todescribe one element or feature's relationship to another element(s) orfeature(s) as illustrated in the figures. It will be understood that thespatially relative terms are intended to encompass differentorientations of the device in use or operation in addition to theorientation depicted in the figures. For example, if a device in thefigures is inverted, elements described as “under” or “beneath” otherelements or features would then be oriented “over” the other elements orfeatures. Thus, the exemplary term “under” can encompass both anorientation of over and under. The device may be otherwise oriented(rotated 90 degrees or at other orientations) and the spatially relativedescriptors used herein interpreted accordingly. Similarly, the terms“upwardly”, “downwardly”, “vertical”, “horizontal” and the like are usedherein for the purpose of explanation only unless specifically indicatedotherwise.

Although the terms “first” and “second” may be used herein to describevarious features/elements (including steps), these features/elementsshould not be limited by these terms, unless the context indicatesotherwise. These terms may be used to distinguish one feature/elementfrom another feature/element. Thus, a first feature/element discussedbelow could be termed a second feature/element, and similarly, a secondfeature/element discussed below could be termed a first feature/elementwithout departing from the teachings of the present invention.

Throughout this specification and the claims which follow, unless thecontext requires otherwise, the word “comprise”, and variations such as“comprises” and “comprising” means various components can be co-jointlyemployed in the methods and articles (e.g., compositions and apparatusesincluding device and methods). For example, the term “comprising” willbe understood to imply the inclusion of any stated elements or steps butnot the exclusion of any other elements or steps.

In general, any of the apparatuses and methods described herein shouldbe understood to be inclusive, but all or a sub-set of the componentsand/or steps may alternatively be exclusive, and may be expressed as“consisting of” or alternatively “consisting essentially of” the variouscomponents, steps, sub-components or sub-steps.

As used herein in the specification and claims, including as used in theexamples and unless otherwise expressly specified, all numbers may beread as if prefaced by the word “about” or “approximately,” even if theterm does not expressly appear. The phrase “about” or “approximately”may be used when describing magnitude and/or position to indicate thatthe value and/or position described is within a reasonable expectedrange of values and/or positions. For example, a numeric value may havea value that is +/−0.1% of the stated value (or range of values), +/−1%of the stated value (or range of values), +/−2% of the stated value (orrange of values), +/−5% of the stated value (or range of values), +/−10%of the stated value (or range of values), etc. Any numerical valuesgiven herein should also be understood to include about or approximatelythat value, unless the context indicates otherwise. For example, if thevalue “10” is disclosed, then “about 10” is also disclosed. Anynumerical range recited herein is intended to include all sub-rangessubsumed therein. It is also understood that when a value is disclosedthat “less than or equal to” the value, “greater than or equal to thevalue” and possible ranges between values are also disclosed, asappropriately understood by the skilled artisan. For example, if thevalue “X” is disclosed the “less than or equal to X” as well as “greaterthan or equal to X” (e.g., where X is a numerical value) is alsodisclosed. It is also understood that the throughout the application,data is provided in a number of different formats, and that this data,represents endpoints and starting points, and ranges for any combinationof the data points. For example, if a particular data point “10” and aparticular data point “15” are disclosed, it is understood that greaterthan, greater than or equal to, less than, less than or equal to, andequal to 10 and 15 are considered disclosed as well as between 10 and15. It is also understood that each unit between two particular unitsare also disclosed. For example, if 10 and 15 are disclosed, then 11,12, 13, and 14 are also disclosed.

Although various illustrative embodiments are described above, any of anumber of changes may be made to various embodiments without departingfrom the scope of the invention as described by the claims. For example,the order in which various described method steps are performed mayoften be changed in alternative embodiments, and in other alternativeembodiments one or more method steps may be skipped altogether. Optionalfeatures of various device and system embodiments may be included insome embodiments and not in others. Therefore, the foregoing descriptionis provided primarily for exemplary purposes and should not beinterpreted to limit the scope of the invention as it is set forth inthe claims.

The examples and illustrations included herein show, by way ofillustration and not of limitation, specific embodiments in which thesubject matter may be practiced. As mentioned, other embodiments may beutilized and derived there from, such that structural and logicalsubstitutions and changes may be made without departing from the scopeof this disclosure. Such embodiments of the inventive subject matter maybe referred to herein individually or collectively by the term“invention” merely for convenience and without intending to voluntarilylimit the scope of this application to any single invention or inventiveconcept, if more than one is, in fact, disclosed. Thus, althoughspecific embodiments have been illustrated and described herein, anyarrangement calculated to achieve the same purpose may be substitutedfor the specific embodiments shown. This disclosure is intended to coverany and all adaptations or variations of various embodiments.Combinations of the above embodiments, and other embodiments notspecifically described herein, will be apparent to those of skill in theart upon reviewing the above description.

1.-20. (canceled)
 21. An apparatus comprising: a cartridge having anon-cylindrical shape and comprising: a heater chamber having a firstside and a second side opposite the first side; a first heater contactcomprising a first exposed heater contact tab and a first fixation site,the first fixation site disposed proximate to the first side; a secondheater contact comprising a second exposed heater contact tab and asecond fixation site, the second fixation site disposed proximate to thesecond side; a wick; and a resistive heating element in contact with thewick, the resistive heating element attached to the first fixation siteand the second fixation site, wherein the wick and the resistive heatingelement are suspended between the first fixation site and the secondfixation site, and wherein the resistive heating element is configuredto generate an aerosol from a vaporizable material; and a body having anon-cylindrical shape and comprising: a cartridge receptacle configuredto insertably receive the cartridge, the heater chamber disposed withinthe cartridge receptacle when the cartridge is insertably receivedwithin the cartridge receptacle; a first receptacle contact positionedto electrically couple with one of the first exposed heater contact taband the second exposed heater contact tab, when the cartridge isinsertably received within the cartridge receptacle; and a secondreceptacle contact positioned to electrically couple with the other ofthe first exposed heater contact tab and the second exposed heatercontact tab, when the cartridge is insertably received within thecartridge receptacle.
 22. The apparatus of claim 21, wherein the firstexposed heater contact tab comprises a first surface area disposed at athird side of the cartridge, wherein the second exposed heater contacttab comprises a second surface area disposed at the third side, andwherein the third side is substantially perpendicular to the first sideof the cartridge and substantially perpendicular the second side of thecartridge.
 23. The apparatus of claim 22, wherein the first surface areaand the second surface area are disposed in a plane parallel to thethird side of the cartridge.
 24. The apparatus of claim 21, wherein thecartridge further comprises: a plastic enclosure configured to receiveand further define the heater chamber, the first heater contact furthercomprising a first surface disposed to further define the heaterchamber, the first side comprising the first surface, the second heatercontact further comprising a second surface disposed to further definethe heater chamber, the second side comprising the second surface. 25.The apparatus of claim 24, wherein the plastic enclosure comprises: afirst opening, the first heater contact extending through the firstopening, the first exposed heater contact tab disposed outside of theheater chamber, the first fixation site disposed within the heaterchamber and proximate to the first surface; and a second opening, thesecond heater contact extending through the second opening, the secondexposed heater contact tab disposed outside of the heater chamber, thesecond fixation site disposed within the heater chamber and proximate tothe second surface.
 26. The apparatus of claim 24, wherein the resistiveheating element comprises: a coil wrapped around the wick; a first endextending from the coil, the first end attached to the first fixationsite; and a second end extending from the coil, the second end attachedto the second fixation site.
 27. The apparatus of claim 26, wherein atleast a portion of the first end is disposed between the first surfaceof the first heater contact and the first side of the heater chamber,and wherein at least a portion of the second end is disposed between thesecond surface of the second heater contact and the second side of theheater chamber.
 28. The apparatus of claim 26, wherein the first end isattached to the first fixation site by tensile force, and wherein thesecond end is attached to the second fixation site by tensile force. 29.The apparatus of claim 24, wherein the first surface and the secondsurface define a volume therebetween, at least a portion of the wick andat least a portion of the resistive heating element disposed within thevolume.
 30. The apparatus of claim 24, wherein the cartridge furthercomprises: a first shape formed from electrically conductive material,the first shape comprising the first heater contact; and a second shapeformed from electrically conductive material, the second shapecomprising the second heater contact, the first shape substantially thesame as the second shape.
 31. The apparatus of claim 21, wherein thefirst heater contact and the second heater contact are configured tocomplete an electrical circuit with the first receptacle contact and thesecond receptacle contact to provide power to the resistive heatingelement.
 32. The apparatus of claim 21, wherein the wick is configuredto contact the vaporizable material and draw the vaporizable materialtowards the resistive heating element.
 33. The apparatus of claim 21,wherein the cartridge has a proximal end and a distal end opposite theproximal end, and wherein the cartridge further comprises: a mouthpieceat the proximal end, the first heater contact and the second heatercontact positioned proximate to the distal end.
 34. The apparatus ofclaim 33, wherein the first exposed heater contact tab and the secondexposed heater contact tab are disposed in a plane parallel to theproximal end and parallel to the distal end.
 35. The apparatus of claim33, wherein the mouthpiece comprises a condensation chamber, and whereinthe mouthpiece further comprises an aerosol outlet in fluidcommunication with the condensation chamber.
 36. The apparatus of claim33, wherein the cartridge further comprises: a storage compartmentconfigured to hold the vaporizable material, the storage compartmentcomprising four exterior walls between the distal end and the proximalend.
 37. The apparatus of claim 36, wherein the four exterior walls aredisposed to form a generally rectangular shape.
 38. The apparatus ofclaim 36, wherein the mouthpiece is opaque and the vaporizable materialis visible through a surface of the storage compartment.
 39. Theapparatus of claim 21, wherein the first heater contact and the secondheater contact comprise a heat sink configured to absorb and dissipateheat produced by the resistive heating element.
 40. A cartridge forinsertion into a receptacle of a vaporizer device, the cartridge havinga non-cylindrical shape and comprising: a heater chamber having a firstside and a second side opposite the first side, the heater chamberconfigured to be disposed within the receptacle when the cartridge isinserted into the cartridge receptacle; a first heater contactcomprising a first exposed heater contact tab and a first fixation site,the first fixation site disposed proximate to the first side, the firstexposed heater contact tab positioned and configured to electricallycouple with one of a first receptacle contact within the receptacle anda second receptacle contact within the receptacle, when the cartridge isinserted into the receptacle; a second heater contact comprising asecond exposed heater contact tab and a second fixation site, the secondfixation site disposed proximate to the second side, the second exposedheater contact tab positioned and configured to electrically couple withthe other of the first receptacle contact and the second receptaclecontact, when the cartridge is inserted into the receptacle; a wick; anda resistive heating element in contact with the wick, the resistiveheating element attached to the first fixation site and the secondfixation site, wherein the wick and the resistive heating element aresuspended between the first fixation site and the second fixation site,and wherein the resistive heating element is configured to generate anaerosol from a vaporizable material.